Transformer and method of manufacturing the same

Abstract

The application discloses a transformer and a manufacturing method thereof. The transformer comprises a magnetic core including magnetic columns; at least two windings, each winding being wound around the outer periphery of a corresponding magnetic column, each winding comprising a main body part in a spiral shape and a wire outlet end connected to both ends of the main body part; a shielding layer, each shielding layer corresponding to the main body part of a corresponding winding; a potting mold, the windings and the magnetic core being located in the potting mold; and a first magnetic member arranged on the outer periphery side of the main body part of at least one winding, the first magnetic member being covered by the shielding layer, and the first magnetic member being used for mutual adsorption with a second magnetic member outside the potting mold to limit at least one winding. According to the transformer provided by the application, effective limiting of the windings can be provided during the potting process, and the problem that air is easily hidden between the windings can be effectively solved.

Description

Technical Field

[0001] This application relates to the field of electromagnetic devices, and in particular to a transformer and its manufacturing method. Background Technology

[0002] A transformer consists of a magnetic core and at least two windings. During the transformer manufacturing process, the assembled magnetic core and windings are placed in a potting mold and potting compound is poured in to encapsulate the components within the transformer. During the potting process, at least one winding needs to be positioned to prevent the potting compound from squeezing the winding and causing it to shift, which could lead to changes in the insulation distance.

[0003] In related technologies, rigid spacers or supports are set between different windings to limit the windings during the potting process. However, it is difficult to ensure that the spacers or supports fit completely without any space between them and the windings, and there are also spaces inside the spacers or supports themselves. The air in these spaces is not easy to be expelled during the potting process, resulting in air still being trapped between different windings after potting is completed. Therefore, the above-mentioned method of limiting the windings during the potting process by using spacers or supports can easily affect the insulation performance of the components inside the transformer. Summary of the Invention

[0004] This application provides a transformer and its manufacturing method, which can effectively limit the windings during the potting process while effectively solving the problem of air easily getting trapped between different windings.

[0005] In a first aspect, embodiments of this application provide a transformer, comprising: a magnetic core including a magnetic column; at least two windings, each winding being wound around the outer periphery of a corresponding magnetic column, each winding including a helical main body and lead-out terminals connected to both ends of the main body; a shielding layer, each shielding layer corresponding to the main body of one winding; a potting mold, the windings and the magnetic core being located in the potting mold; and a first magnetic element disposed on the outer periphery of the main body of at least one winding, the first magnetic element being covered by the shielding layer, the first magnetic element being used to attract each other with a second magnetic element outside the potting mold to limit the movement of at least one winding.

[0006] A transformer according to an embodiment of this application includes a first magnetic element disposed on the outer periphery of the main body of at least one winding, and the first magnetic element is covered by a shielding layer. During transformer potting, the first magnetic element can attract a second magnetic element outside the potting mold, using magnetic attraction to limit the corresponding winding, preventing the potting compound from squeezing the winding and causing it to shift, thus ensuring accurate insulation distance between different windings. By limiting the windings with magnetic attraction, rigid spacers or supports are eliminated between different windings, thereby avoiding the problem of air trapped between different windings after potting caused by the use of spacers or supports, further improving the yield of the potted transformer.

[0007] According to the foregoing embodiments of the first aspect of this application, the transformer further includes: potting compound, located in the potting mold, the potting compound being filled between the different windings.

[0008] According to any of the foregoing embodiments of the first aspect of this application, at least two first magnetic elements are provided on the outer periphery of the main body of the winding, and the at least two first magnetic elements are distributed at different positions in the circumferential direction of the main body.

[0009] According to any of the foregoing embodiments of the first aspect of this application, two first magnetic elements are provided on the outer periphery of the main body of the winding, and the two first magnetic elements are symmetrically distributed along the circumference of the main body.

[0010] According to any of the foregoing embodiments of the first aspect of this application, the first magnetic element is a conductive structure, the first magnetic element is in contact with the shielding layer, and all the first magnetic elements correspondingly disposed on the outer peripheral side of the same main body are electrically connected to the same output terminal of the corresponding winding through connecting lines.

[0011] According to any of the foregoing embodiments of the first aspect of this application, the transformer further includes: a third magnetic element fixedly connected to the magnetic core, the third magnetic element being used to attract each other to a fourth magnetic element outside the potting mold to limit the magnetic core.

[0012] According to any of the foregoing embodiments of the first aspect of this application, the at least two windings are arranged side by side along the axial direction, each winding is provided with a corresponding first magnetic element, wherein the first magnetic element is attached to the outer peripheral surface of the main body, and the shielding layer covers the corresponding main body and the corresponding first magnetic element.

[0013] According to any of the foregoing embodiments of the first aspect of this application, the magnetic core is a canned magnetic core, the winding is installed inside the magnetic core, the first magnetic element is attached to the outer peripheral surface of the magnetic core, and the shielding layer covers the magnetic core, the winding, and the first magnetic element.

[0014] According to any of the foregoing embodiments of the first aspect of this application, the at least two windings include a first winding and a second winding, the first winding is fixedly sleeved on the magnetic post of the magnetic core, the second winding is arranged around the outer periphery of the first winding, and the first magnetic element is arranged on the outer periphery of the main body of the second winding.

[0015] Secondly, embodiments of this application provide a method for manufacturing a transformer, comprising: providing a first magnetic element on the outer periphery of the main body portion of at least one winding; forming a shielding layer on the outer side of the main body portion of each winding, wherein the shielding layer covers the first magnetic element; assembling the winding and a magnetic core; placing the assembled winding and the magnetic core in a potting mold; fixing a second magnetic element at a first target position on the outer wall of the potting mold, wherein the second magnetic element and the corresponding first magnetic element attract each other to limit the movement of at least one winding; filling the potting mold with potting adhesive and allowing the potting adhesive to cure; and removing the second magnetic element after the potting adhesive has cured.

[0016] According to the transformer manufacturing method of this application embodiment, a first magnetic component is provided on the outer periphery of the main body of at least one winding. During potting, a second magnetic component is fixedly connected to a first target position on the outer wall of the potting mold. After the assembled winding and magnetic core are placed in the potting mold, the first magnetic component and the corresponding second magnetic component attract each other, thereby limiting the position of at least one winding and preventing the potting compound from squeezing the winding and causing it to shift during filling, thus ensuring an accurate insulation distance between different windings. The above manufacturing method limits the winding position through magnetic attraction, eliminating the need for rigid spacers or supports between different windings. This avoids the problem of air easily trapped between different windings after potting caused by the use of spacers or supports, thereby further improving the yield of the transformer after potting.

[0017] According to the foregoing embodiments of the second aspect of this application, before the step of filling the potting compound into the potting mold and curing the potting compound, the method of manufacturing the transformer further includes: fixing a third magnetic component to the magnetic core; and fixing a fourth magnetic component to a second target position on the outer wall of the potting mold, wherein the fourth magnetic component can attract each other with the corresponding third magnetic component placed in the potting mold to limit the magnetic core, and the method of manufacturing the transformer further includes: removing the fourth magnetic component after the potting compound has cured. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, 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 this application. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0019] Figure 1 This is a perspective view of the first embodiment of the transformer in this application;

[0020] Figure 2 This is a three-dimensional schematic diagram of the windings and shielding layer in the first embodiment of the transformer of this application;

[0021] Figure 3 This is a three-dimensional schematic diagram of the winding and the first magnetic component in the first embodiment of the transformer of this application;

[0022] Figure 4 This is a three-dimensional schematic diagram of the potting process in the first embodiment of the transformer of this application;

[0023] Figure 5 This is a perspective view of the second embodiment of the transformer in this application;

[0024] Figure 6 This is a three-dimensional schematic diagram of the potting process in the second embodiment of the transformer of this application;

[0025] Figure 7 This is a perspective view of the third embodiment of the transformer in this application;

[0026] Figure 8 This is a three-dimensional schematic diagram of the potting process in the third embodiment of the transformer of this application.

[0027] Explanation of reference numerals in the attached figures:

[0028] 100 - Transformer;

[0029] 110 - Magnetic core; 111 - Magnetic column;

[0030] 120 - Winding; 121 - Main body; 122 - Outgoing terminal; 120a - First winding; 120b - Second winding;

[0031] 130 - Shielding layer;

[0032] 140 - First magnetic component;

[0033] 150-Connecting cable;

[0034] 160 - Third magnetic component;

[0035] 190 - Filling mold;

[0036] 220 - Second magnetic component;

[0037] 230 - Fourth magnetic component.

[0038] The purpose, features, and advantages of this application will be further explained in conjunction with the embodiments and the accompanying drawings. Detailed Implementation

[0039] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0040] It should be noted that all directional indications in the embodiments of this application, such as up, down, left, right, front, back, etc., are only used to explain the relative positional relationship and movement of the components in a specific posture as shown in the attached figure. If the specific posture changes, the directional indication will also change accordingly.

[0041] Furthermore, the use of terms such as "first" and "second" in this application is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. Additionally, the technical solutions of the various embodiments can be combined with each other, but only on the basis of being achievable by those skilled in the art. When the combination of technical solutions is contradictory or impossible to implement, such a combination of technical solutions should be considered non-existent and not within the scope of protection claimed in this application.

[0042] This application provides a transformer and a method for manufacturing the same. In this document, the term "transformer" can refer to a finished transformer that has been manufactured, or to a semi-finished transformer obtained at various stages of the transformer manufacturing process.

[0043] Figure 1 This is a perspective view of the first embodiment of the transformer of this application. The transformer 100 includes a magnetic core 110, at least two windings, a shielding layer 130, a first magnetic element, and a potting mold. The magnetic core 110 includes magnetic posts 111. Each winding is wound around the outer periphery of a corresponding magnetic post 111.

[0044] Figure 2 This is a three-dimensional schematic diagram of the windings and shielding layer in the first embodiment of the transformer of this application. Figure 3This is a perspective view of the windings and the first magnetic component in the first embodiment of the transformer of this application. Each winding 120 includes a helical main body 121 and lead-out terminals connected to both ends of the main body 121. Each winding 120 typically includes two lead-out terminals 122. Each shielding layer 130 covers the main body 121 of a corresponding winding 120. The shielding layer 130 may be semiconductor paper.

[0045] like Figure 3 The first magnetic element 140 is disposed on the outer periphery of the main body portion 121 of at least one winding 120, and the first magnetic element 140 is covered by a shielding layer 130.

[0046] Figure 4 This is a perspective view of the potting process in the first embodiment of the transformer of this application. During potting, the winding 120 and the magnetic core 110 are placed in the potting mold 190. A second magnetic element 220 is fixedly connected to a first target position on the outer wall of the potting mold 190. The potting process includes filling the potting mold 190 with potting compound and allowing the potting compound to cure. In this embodiment, the winding 120 and the magnetic core 110 are located in the potting mold 190, and the first magnetic element 140 is used to attract each other with the second magnetic element 220 outside the potting mold 190 to limit the position of at least one winding 120.

[0047] The first magnetic component 140 can be a ferromagnetic material or a permanent magnet. The second magnetic component 220 is a magnet that is magnetically attracted to the corresponding first magnetic component 140.

[0048] The transformer 100 according to an embodiment of this application includes a first magnetic element 140, which is disposed on the outer periphery of the main body 121 of at least one winding 120, and is covered by a shielding layer 130. During potting of the transformer 100, the first magnetic element 140 can attract to a second magnetic element 220 outside the potting mold 190. The magnetic attraction limits the corresponding winding 120, preventing the potting compound from squeezing and displacing the winding 120, thus ensuring accurate insulation distance between different windings 120. By limiting the winding 120 with magnetic attraction, rigid spacers or supports between different windings 120 are eliminated, avoiding the problem of air easily trapped between different windings 120 after potting caused by the use of spacers or supports, thereby further improving the yield of the potted transformer 100.

[0049] In some embodiments, after the potting process, the transformer 100 includes potting compound, which is located in the potting mold 190. The potting compound is filled between different windings 120, thereby ensuring an accurate insulation distance between different windings 120 and ensuring that the windings 120 have a stable position in the transformer 100. The potting compound can fully fill the space between the windings 120 and different windings 120, thereby avoiding the problem of air easily being trapped between different windings 120.

[0050] In some embodiments, after potting is completed, the second magnetic element 220 can be removed from the outer wall of the potting mold 190, which also serves as the outer casing of the transformer 100.

[0051] like Figure 3 In some embodiments, at least two first magnetic elements 140 are provided on the outer periphery of the main body 121 of the winding 120, and the at least two first magnetic elements 140 are distributed at different positions around the main body 121. During the potting process, the second magnetic element 220 corresponds one-to-one with the first magnetic element 140. In the above embodiments, by distributing the first magnetic elements 140 at different positions around the main body 121, during the potting process, the attraction between the second magnetic element 220 and the first magnetic element 140 provides a limiting effect at different positions around the main body 121, thereby ensuring a stronger limiting effect on the winding 120, reducing the possibility of displacement, swaying, or rotation of the winding 120, and improving the positional accuracy of the winding 120 during the potting process of the transformer 100.

[0052] like Figure 3 In some embodiments, two first magnetic elements 140 are provided on the outer periphery of the main body 121 of the winding 120, and the two first magnetic elements 140 are symmetrically distributed circumferentially along the main body 121. By using the two symmetrically distributed first magnetic elements 140, high-precision positioning of the winding 120 can be achieved with less positioning material.

[0053] like Figure 3In some embodiments, the potting mold 190 is a cuboid with an opening at one end. In one example, the potting mold 190 is a cuboid with an opening at the top, through which the winding 120 and the magnetic core 110 can be placed, and the potting compound can also be filled into the potting mold 190 via the top opening. The potting mold 190 is a cuboid with an opening at the top and has four sides. In some embodiments, two first magnetic elements 140 are provided on the outer periphery of the main body 121 of each winding 120, that is, the first magnetic elements 140 on each winding 120 are arranged in pairs, and correspondingly, the second magnetic elements 220 are also arranged in pairs. In this embodiment, each pair of second magnetic elements 220 is disposed on two opposite sides of the potting mold 190. In the height direction, the second magnetic elements 220 are located at the middle of the side of the potting mold 190. This allows for high-precision positioning of each winding 120 with a smaller number of magnetic elements. In some embodiments, under the mutual attraction between the second magnetic elements 220 and the first magnetic elements 140, the shielding layer 130 contacts the inner wall of the potting mold 190. The contact between the shielding layer 130 and the inner wall of the potting mold 190 further improves the stability of the winding 120's position within the potting mold 190.

[0054] like Figure 2 , Figure 3 In some embodiments, the first magnetic element 140 is a conductive structure and is in contact with the shielding layer 130. All the first magnetic elements 140 correspondingly disposed on the outer periphery of the same main body 121 are electrically connected to the same output terminal 122 of the corresponding winding 120 through connecting lines 150.

[0055] The connecting wire 150 can be any type of conductor. In one example, the connecting wire 150 is a copper wire with both ends stripped and tinned, and both ends of the copper wire are soldered to the first magnetic component 140 and the lead-out end 122, respectively.

[0056] In this embodiment, the first magnetic element 140 can be a ferromagnetic conductor, possessing both magnetism and conductivity. Besides serving as a limiting element during the potting process, the first magnetic element 140 also functions as a potential lead-out electrical connection structure for the shielding layer 130. The first magnetic element 140 electrically connects the shielding layer 130 to one output terminal 122 of the winding 120, thereby ensuring the introduction of potential into the shielding layer 130 and realizing the electric field shielding function of the shielding layer 130.

[0057] like Figure 1 In some embodiments, the transformer 100 further includes a third magnetic element 160, which is fixedly connected to the magnetic core 110. For example... Figure 4During the sealing process, a detachable fourth magnet 230 may be provided on the outside of the sealing mold 190. During sealing, a third magnetic component 160 is used to attract the fourth magnetic component 230 on the outside of the sealing mold 190 to limit the magnetic core 110. The third magnetic component 160 can be a ferromagnetic material or a permanent magnet. The fourth magnetic component 230 is a magnet that is magnetically attracted to the corresponding third magnetic component 160.

[0058] like Figure 4 When potting the transformer 100, the third magnetic component 160 can attract each other to the external fourth magnetic component 230. The magnetic attraction makes the corresponding magnetic core 110 limited, preventing the potting glue from squeezing the magnetic core 110 and causing it to shift, thereby improving the positional accuracy of the magnetic core 110 during the potting process of the transformer 100.

[0059] In some embodiments, after potting is completed, the fourth magnetic element 230 can be removed from the outer wall of the potting mold 190, which also serves as the outer casing of the transformer 100.

[0060] like Figures 1 to 4 In the first embodiment, the winding 120 and the magnetic core 110 are separately arranged. In the first embodiment, at least two windings 120 are arranged side by side along the axial direction. Each winding 120 is provided with a corresponding first magnetic element 140, wherein the first magnetic element 140 is attached to the outer peripheral surface of the main body 121. The shielding layer 130 covers the corresponding outer peripheral surface of the main body 121 and the corresponding first magnetic element 140. Figures 1 to 3 In one example, the transformer 100 includes two windings 120, namely a primary winding 120 and a secondary winding 120, which are arranged side by side along the axial direction. A first magnetic element 140 is attached to the outer peripheral surface of each winding 120. Further, in some embodiments, at least two first magnetic elements 140 are attached to the outer peripheral surface of each winding 120, for example, two symmetrically arranged first magnetic elements 140. Each winding 120 corresponds to a shielding layer 130, which covers the main body 121 and the first magnetic element 140 of a corresponding winding 120, exposing the lead end 122.

[0061] In the above embodiment, for the transformer 100 configuration in which the winding 120 and the magnetic core 110 are separately arranged and the windings 120 are arranged in parallel along the axial direction, the first magnetic element 140 is directly attached to the outer peripheral surface of the main body 121, and the shielding layer 130 covers the corresponding outer peripheral surface of the main body 121 and the corresponding first magnetic element 140. During the potting process, it can provide effective limiting of each winding 120, and at the same time effectively solve the problem that air is easily trapped between different windings 120.

[0062] like Figure 1In the first embodiment, the transformer 100 further includes a third magnetic element 160. The third magnetic element 160 is fixedly connected to the magnetic core 110. Figure 4 During the potting process, a detachable fourth magnet 230 is provided on the outside of the potting mold 190. A third magnetic element 160 is used to attract each other with the fourth magnetic element 230 on the outside of the potting mold 190 to limit the magnetic core 110. The third magnetic element 160 is attached to the end face of at least one end of the magnetic core 110 along the axial direction.

[0063] In one example, the transformer 100 includes two windings 120, and the magnetic core 110 includes two cores corresponding to the two windings 120. Optionally, each magnetic core 110 is provided with at least one third magnetic element 160. During the potting process, a fourth magnetic element 230 corresponds to the third magnetic element 160. By providing the third magnetic element 160 on the magnetic core 110, during potting, the corresponding magnetic core 110 is limited by magnetic attraction, improving the positional accuracy of the magnetic core 110 during the potting process of the transformer 100.

[0064] Figure 5 This is a perspective view of the second embodiment of the transformer of this application. To clearly show the internal structure covered by the shielding layer in the second embodiment, Figure 5 The shielding layer is shown transparently, and its outline is indicated by dashed lines. In the second embodiment, the magnetic core 110 is a canned magnetic core 110, the winding 120 is installed inside the magnetic core 110, the first magnetic element 140 is attached to the outer peripheral surface of the magnetic core 110, and the shielding layer 130 covers the corresponding magnetic core 110, the corresponding winding 120, and the corresponding first magnetic element 140.

[0065] Figure 6 This is a three-dimensional schematic diagram of the potting process in the second embodiment of the transformer of this application. To clearly show the internal structure covered by the shielding layer in the second embodiment, Figure 6 The shielding layer is shown in the diagram with the image partially obscured. During potting, the assembled winding 120 and magnetic core 110 are placed in a potting mold 190. A detachable second magnetic component 220 can be connected to the outside of the potting mold 190. A first magnetic component 140 is used to attract the second magnetic component 220 outside the potting mold 190 to limit the position of at least one winding 120. The potting process includes filling the potting mold 190 with potting compound and allowing the potting compound to cure. In the above embodiment, for the transformer 100 configuration with canned magnetic core 110, each shielding layer 130 simultaneously covers the corresponding magnetic core 110, winding 120, and first magnetic component 140. At this time, the first magnetic component 140 has the function of limiting the position of winding 120 and magnetic core 110 during the potting process, while ensuring the positional stability of winding 120 and magnetic core 110 during the potting process.

[0066] Figure 7This is a perspective view of the third embodiment of the transformer in this application. To clearly show the internal structure covered by the shielding layer in the third embodiment, Figure 7 The shielding layer is omitted from the drawing. In the third embodiment, at least two windings 120 include a first winding 120a and a second winding 120b. The first winding 120a is fixedly sleeved on the magnetic post 111 of the magnetic core 110, and the second winding 120b is arranged around the outer periphery of the first winding 120a. A first magnetic element 140 is disposed on the outer periphery of the main body 121 of the second winding 120b.

[0067] In one example, the first winding 120a is the primary winding 120, which is fixedly sleeved on the magnetic post 111 of the magnetic core 110, and the second winding 120b is the secondary winding 120. In other embodiments, the first winding 120a can be a secondary winding, the second winding 120b can be a primary winding, and the first winding 120a can be fixedly sleeved on the magnetic post 111 of the magnetic core 110.

[0068] Figure 8 This is a three-dimensional schematic diagram of the potting process in the third embodiment of the transformer of this application. To clearly show the internal structure covered by the shielding layer in the third embodiment, Figure 8 The shielding layer is shown in the diagram without being explicitly shown. During potting, the assembled winding 120 and magnetic core 110 are placed in a potting mold 190. A detachable second magnetic component 220 can be connected to the outside of the potting mold 190. The potting process includes filling the potting mold 190 with potting compound and allowing the potting compound to cure. When potting the transformer 100, the first magnetic component 140 can attract the second magnetic component 220 outside the potting mold 190, thereby limiting the second winding 120b and preventing the potting compound from squeezing the second winding 120b and causing it to shift. This ensures a stable insulation distance between the first winding 120a and the second winding 120b. Since the second winding 120b is limited by the magnetic attraction of the first magnetic element 140 and the second magnetic element 220, there is no need to set a rigid spacer or support between the first winding 120a and the second winding 120b, thereby avoiding the problem of air being easily trapped between different windings 120 after potting caused by setting spacers or supports.

[0069] like Figure 7 In the third embodiment, the transformer 100 further includes a third magnetic element 160. The third magnetic element 160 is fixedly connected to the magnetic core 110 and is used to attract each other with a fourth magnetic element 230 outside the potting mold 190 to limit the magnetic core 110. The third magnetic element 160 is attached to the end face of at least one end of the magnetic core 110 along the axial direction of the magnetic post 111.

[0070] In the above embodiment, the first winding 120a is fixedly sleeved on the magnetic post 111 of the magnetic core 110, and the third magnetic component 160 can be attracted to the external fourth magnetic component 230, thereby limiting the magnetic core 110 and the first winding 120a and improving the positional accuracy of the magnetic core 110 and the first winding 120a during the potting process of the transformer 100.

[0071] This application also provides a method for manufacturing a transformer, used to manufacture the transformer 100 described in the above embodiments. The method for manufacturing the transformer in this application includes the following steps:

[0072] In step S101, a first magnetic element 140 is provided on the outer periphery of the main body portion 121 of at least one winding 120. The first magnetic element 140 may be a ferromagnetic material or a permanent magnet.

[0073] In step S102, a shielding layer 130 is formed on the outside of the main body 121 of each winding 120, wherein the shielding layer 130 covers the first magnetic element 140. The shielding layer 130 may be semiconductor paper.

[0074] In step S103, the winding 120 is assembled with the magnetic core 110.

[0075] In step S104, the assembled winding 120 and magnetic core 110 are placed in the potting mold 190.

[0076] In step S105, a second magnetic element 220 is fixedly connected to a first target position on the outer wall of the potting mold 190. The second magnetic element 220 is a magnet that is magnetically attracted to the corresponding first magnetic element 140. The second magnetic element 220 and the corresponding first magnetic element 140 attract each other to limit at least one winding 120.

[0077] In step S106, potting compound is filled into the potting mold 190 and allowed to cure. The potting compound may be epoxy resin.

[0078] In step S107, the second magnetic component 220 is removed after the potting compound has cured.

[0079] Before filling and potting the transformer 100 in step S106, the order of steps S101, S102, S103, S104 and S105 may be arranged differently depending on the shape of the transformer 100. Some of these steps may also be performed simultaneously or alternately.

[0080] According to the manufacturing method of the transformer 100 in this application embodiment, a first magnetic element 140 is provided on the outer periphery of the main body 121 of at least one winding 120. During potting, a second magnetic element 220 is fixedly connected to a first target position on the outer wall of the potting mold 190. After the assembled winding 120 and magnetic core 110 are placed in the potting mold 190, the first magnetic element 140 and the corresponding second magnetic element 220 attract each other, thereby limiting the position of at least one winding 120 and preventing the potting compound from squeezing the winding 120 and causing it to shift when filling, thus ensuring an accurate insulation distance between different windings 120. The above manufacturing method limits the winding 120 by magnetic attraction, eliminating the need to set rigid spacers or supports between different windings 120, thereby avoiding the problem of air easily trapped between different windings 120 after potting caused by setting spacers or supports, and further improving the yield of the transformer 100 after potting.

[0081] In some embodiments, before step S106 of filling the potting compound into the potting mold 190 and curing the potting compound, the method of manufacturing the transformer 100 may further include steps S108 and S109.

[0082] In step S108, a third magnetic component 160 is fixedly connected to the magnetic core 110. The third magnetic component 160 can be a ferromagnetic material or a permanent magnet.

[0083] In step S109, a fourth magnetic component 230 is fixedly connected to the second target position on the outer wall of the potting mold 190. The fourth magnetic component 230 can attract each other with the corresponding third magnetic component 160 placed in the potting mold 190 to limit the magnetic core 110. The fourth magnetic component 230 is a magnet that is magnetically attracted to the corresponding third magnetic component 160.

[0084] At this point, the manufacturing method of transformer 100 may also include step S110. In step S110, the fourth magnetic component 230 is removed after the potting compound has cured.

[0085] Before filling and potting the transformer 100 in step S106, the order of steps S101, S102, S103, S104, S105, S108, and S109 may vary depending on the shape of the transformer 100. Some of these steps may also be performed simultaneously or alternately.

[0086] In the above embodiment, when the transformer 100 is potted, the third magnetic component 160 can be attracted to the external fourth magnetic component 230. The magnetic attraction force limits the corresponding magnetic core 110, preventing the potting glue from squeezing the magnetic core 110 and causing it to shift, thereby improving the positional accuracy of the magnetic core 110 during the potting process of the transformer 100.

[0087] The above description is merely a preferred embodiment of this application and does not limit the patent scope of this application. Any equivalent structural transformations made based on the concept of this application and the contents of the specification and drawings of this application, or direct / indirect applications in other related technical fields, are included within the patent protection scope of this application.

Claims

1. A transformer, characterized in that, include: Magnetic core, including magnetic pillars; At least two windings, each winding being wound around the outer periphery of the corresponding magnetic post, each winding including a helical main body and an output terminal connected to both ends of the main body; Each shielding layer covers the main body portion corresponding to one of the windings; A potting mold, wherein the winding and the magnetic core are located in the potting mold; A first magnetic element is disposed on the outer periphery of the main body portion of at least one of the windings. The first magnetic element is covered by the shielding layer. The first magnetic element is used to attract each other with a second magnetic element outside the potting mold to limit the movement of at least one of the windings.

2. The transformer as described in claim 1, characterized in that, Also includes: A potting compound is located in the potting mold and is filled between the different windings.

3. The transformer as described in claim 1, characterized in that, At least two first magnetic elements are provided on the outer periphery of the main body of the winding, and the at least two first magnetic elements are distributed at different positions around the main body.

4. The transformer as described in claim 3, characterized in that, Two first magnetic elements are provided on the outer periphery of the main body of the winding, and the two first magnetic elements are symmetrically distributed along the circumference of the main body.

5. The transformer as described in claim 1, characterized in that, The first magnetic component is a conductive structure and is in contact with the shielding layer. All the first magnetic components corresponding to the outer periphery of the same main body are electrically connected to the same output terminal of the corresponding winding through connecting lines.

6. The transformer as described in claim 1, characterized in that, Also includes: The third magnetic component is fixedly connected to the magnetic core. The third magnetic component is used to attract each other to the fourth magnetic component outside the potting mold to limit the magnetic core.

7. The transformer as described in any one of claims 1 to 6, characterized in that, The at least two windings are arranged side by side along the axial direction, and each winding is provided with a corresponding first magnetic element, wherein the first magnetic element is attached to the outer peripheral surface of the main body, and the shielding layer covers the corresponding main body and the corresponding first magnetic element.

8. The transformer as described in any one of claims 1 to 6, characterized in that, The magnetic core is a canned magnetic core, the winding is installed inside the magnetic core, the first magnetic element is attached to the outer peripheral surface of the magnetic core, and the shielding layer covers the magnetic core, the winding, and the first magnetic element.

9. The transformer as described in any one of claims 1 to 6, characterized in that, The at least two windings include a first winding and a second winding. The first winding is fixedly sleeved on the magnetic post of the magnetic core, and the second winding is arranged around the outer periphery of the first winding. The first magnetic element is arranged on the outer periphery of the main body of the second winding.

10. A method for manufacturing a transformer, characterized in that, include: A first magnetic element is provided on the outer periphery of at least one of the main bodies of the winding; A shielding layer is formed on the outside of the main body portion of each winding, wherein the shielding layer covers the first magnetic element; Assemble the winding with the magnetic core; The assembled winding and magnetic core are placed in the potting mold; A second magnetic component is fixedly connected to a first target position on the outer wall of the potting mold. The second magnetic component and the corresponding first magnetic component attract each other to limit at least one of the windings. Fill the potting mold with potting compound and allow the potting compound to cure; The second magnetic component is removed after the potting compound has cured.

11. The method for manufacturing a transformer as described in claim 10, characterized in that, Before the step of filling the potting compound into the potting mold and allowing the potting compound to cure, the method of manufacturing the transformer further includes: A third magnetic component is fixedly connected to the magnetic core; and A fourth magnetic component is fixedly connected to a second target position on the outer wall of the potting mold, wherein the fourth magnetic component is capable of attracting the corresponding third magnetic component placed in the potting mold to limit the position of the magnetic core. The method for manufacturing the transformer also includes: The fourth magnetic component is removed after the potting compound has cured.

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