A transformer for reducing leakage current

Abstract

The utility model relates to a transformer for reducing leakage current, comprising a transformer skeleton made of electrical insulating material; a secondary winding, a shielding copper layer and a primary winding wound on the skeleton, wherein the secondary winding, the shielding copper layer and the primary winding are arranged in layers of secondary winding, shielding copper layer and primary winding from inside to outside; four or more stays are arranged between the shielding copper layer and the primary winding, the stays have a thickness of 3mm, and one or more stays are respectively arranged in four directions of the transformer skeleton; insulating paper layers are respectively stacked between the secondary winding and the shielding copper layer, between the shielding copper layer and the stays, between the stays and the primary winding, and between each layer of the secondary winding and the primary winding. The utility model solves the technical problem of excessive leakage current of transformer shielding copper in the prior art.

Description

Technical Field

[0001] The present application belongs to the technical field of transformer design, and in particular, relates to a transformer with reduced leakage current. Background Art

[0002] In the field of modern electrical engineering, transformers are one of the core electrical devices used for voltage conversion, current transmission and power control. The design and performance of transformers directly affect the efficiency and safety of the entire electrical system. However, traditional transformer design faces some technical challenges and limitations.

[0003] Traditional transformer design is usually carried out according to fixed product structure standards, which can meet basic power transmission needs in most cases. However, in specific application scenarios, such as when customers have higher requirements for equipment details, this conventional design method may not fully meet the needs. A typical problem is that the leakage current of the transformer shielding copper E to the ground exceeds the standard. Leakage current refers to the phenomenon that under normal working conditions, due to poor insulation or design defects, the current fails to flow completely along the predetermined path, but partially flows to the ground wire. In high-demand applications, excessive leakage current not only affects the performance of the transformer, but may also cause safety risks such as electrical fires and equipment damage.

[0004] In addition, when the leakage current exceeds the limit set by the customer, the transformer may not pass the quality audit and cannot be used in certain high-standard electrical systems. Customers' strict requirements for leakage current are usually based on the optimization of overall performance and compliance with safety standards, especially in areas with high standards for electromagnetic compatibility (EMC) and electrical safety. Therefore, this limitation of traditional transformer design not only limits its scope of application, but may also affect the market competitiveness of the product.

[0005] In view of the above problems, the deficiencies of the existing technology are obvious, and an improved transformer design is urgently needed to effectively reduce leakage current to meet more stringent customer needs and safety standards. Utility Model Content

[0006] In view of the deficiencies existing in the related technologies, the utility model provides a transformer with reduced leakage current, which solves the technical problem of transformer shielding copper leakage in the prior art.

[0007] In a possible implementation, a transformer for reducing leakage current is provided, a transformer skeleton made of an electrical insulating material;

[0008] A primary winding, a shielding copper layer and a secondary winding wound on the frame, wherein the primary winding, the shielding copper layer and the secondary winding are arranged in layers from inside to outside in the order of secondary winding, shielding copper layer and primary winding;

[0009] Four or more stays are arranged between the shielding copper layer and the primary winding, the stays have a thickness of 3 mm, and one or more stays are arranged in four directions of the transformer skeleton respectively;

[0010] Insulating paper layers are stacked between the secondary winding and the shielding copper layer, between the shielding copper layer and the stay, between the stay and the primary winding, and between each layer of the secondary winding and the primary winding;

[0011] The skeleton includes a layer of 0.5 mm thick insulating paper, two layers of 0.14 mm thick insulating paper and two layers of 0.24 mm thick insulating paper.

[0012] A layer of 0.14mm thick insulation paper is set between each layer of the secondary winding;

[0013] Three layers of 0.14mm thick insulating paper are set between the secondary winding and the shielding copper layer;

[0014] Three layers of 0.14mm thick insulating paper are set between the shielding copper layer and the stays;

[0015] Two layers of 0.24 mm thick insulating paper are placed between the stays and the primary winding;

[0016] A layer of 0.14mm thick insulating paper is placed between each layer of the primary winding;

[0017] Two layers of 0.24mm thick insulating paper are set outside the primary winding.

[0018] In a possible implementation manner, a support block is provided on one side of the transformer and is located between the secondary winding and the shielding copper layer. The number of the support blocks is two or more, and the thickness of the support blocks is 8-10 mm.

[0019] In a possible implementation manner, the primary winding and the secondary winding are formed by winding an electrically conductive material; and the shielding copper layer is made of an electrically conductive material.

[0020] In a possible implementation, the support bar is made of a non-conductive and high-temperature resistant plastic or ceramic material.

[0021] In a possible implementation manner, the conductive wires of the primary winding and the secondary winding are made of copper wires with high electrical conductivity and heat resistance.

[0022] In a possible implementation manner, the edge of the shielding copper layer is rounded to avoid excessive electric field concentration at sharp corners.

[0023] In a possible implementation manner, the support block has a thickness of 8 mm.

[0024] Based on the above technical solution, the transformer of the utility model effectively reduces the generation of leakage current and enhances the safety and stability of the equipment by setting the insulating layer and the support bar; it also includes the setting of the support block, which not only enhances the structural stability of the transformer, but also further isolates the leakage path of the current, thereby achieving the purpose of optimizing the electromagnetic field distribution, reducing the leakage current, and improving the safety and stability of the transformer. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of the present application. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation on the present invention. In the drawings:

[0026] Figure 1 This is a schematic structural diagram of a transformer for reducing leakage current according to an implementation mode of the utility model;

[0027] Figure 2 It is a partially enlarged schematic diagram of a transformer for reducing leakage current according to an implementation mode of the utility model.

[0028] In the figure:

[0029] 1. Skeleton; 2. Secondary winding; 21. Secondary winding starting line; 22. Secondary winding ending line; 3. Shielded copper layer; 31. Shielded copper outlet terminal; 4. Primary winding; 41. Primary winding starting line; 42. Primary winding ending line; 5. Secondary winding interlayer insulation paper layer; 6. Shielded copper insulation layer; 7. Support bar-primary winding interlayer insulation layer; 8. Primary winding interlayer insulation layer; 9. Peripheral insulation layer; 10. Support bar; 11. Support block; 12. Temperature switch. DETAILED DESCRIPTION

[0030] The following will be combined with the drawings in the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments of the present application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

[0031] In the description of the present application, it should be understood that the terms "center", "lateral", "longitudinal", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present application.

[0032] The terms "first", "second", and "third" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the technical features indicated. Thus, a feature defined as "first", "second", and "third" may explicitly or implicitly include one or more of the features.

[0033] In the description of this application, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a direct connection, or an indirect connection through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0034] In order to solve the technical problem of transformer shielding copper leakage in the prior art, the present application proposes a transformer with reduced leakage current.

[0035] See also Figure 1 In a possible implementation, a transformer for reducing leakage current is provided, comprising: a transformer skeleton 1 made of an electrical insulating material; a secondary winding 2, a shielding copper layer 3 and a primary winding 4 wound on the skeleton 1, wherein the secondary winding 2, the shielding copper layer 3 and the primary winding 4 are arranged in sequence from inside to outside;

[0036] Four or more stays 10 are arranged between the shielding copper layer 3 and the primary winding 4, the thickness of the stays 10 is 3 mm, and one or more stays 10 are arranged in four directions of the transformer skeleton 1;

[0037] Insulating paper layers are stacked between the secondary winding and the shielding copper layer, between the shielding copper layer and the stay, between the stay and the primary winding, and between each layer of the secondary winding and the primary winding;

[0038] See also Figure 2 , wherein the skeleton 1 includes a layer of 0.5 mm thick insulating paper, two layers of 0.14 mm thick insulating paper and two layers of 0.24 mm thick insulating paper;

[0039] A secondary winding interlayer insulation layer 5 is provided between each layer of the secondary winding, comprising a layer of 0.14 mm thick insulating paper;

[0040] A shielding copper insulation layer 6 is provided between the secondary winding and the shielding copper layer, comprising three layers of 0.14 mm thick insulating paper;

[0041] A shielding copper insulation layer 6 is provided between the shielding copper layer and the stays, comprising three layers of 0.14 mm thick insulating paper;

[0042] A stay-primary winding interlayer insulation layer 7 is provided between the stay and the primary winding, comprising two layers of 0.24 mm thick insulating paper;

[0043] A primary winding interlayer insulation layer 8 is provided between each layer of the primary winding, comprising a layer of insulating paper with a thickness of 0.14 mm;

[0044] An outer peripheral insulation layer 9 is arranged outside the primary winding, which is two layers of 0.24 mm thick insulation paper.

[0045] In the above embodiment, the transformer for reducing leakage current includes a transformer skeleton 1 made of an electrical insulating material; a secondary winding 2, a shielding copper layer 3 and a primary winding 4 wound on the skeleton 1, and these windings are arranged in layers from the inside to the outside, namely, the secondary winding 2, the shielding copper layer 3, and the primary winding 4; and four or more stays 10, these stays 10 have a thickness of 3 mm, and one or more stays 10 are respectively arranged in four directions of the transformer skeleton 1. In addition, the utility model also includes insulating paper layers 5, and these insulating paper layers 5 are respectively stacked between the secondary winding 2 and the shielding copper layer 3, between the shielding copper layer 3 and the stay 10, between the stay 10 and the primary winding 4, and between each layer of the secondary winding 2 and the primary winding 4.

[0046] In the above scheme, the transformer design adopts a specific hierarchical structure, in which the specific arrangement order of the secondary winding 2, the shielding copper layer 3, and the primary winding 4 is intended to effectively reduce electromagnetic interference and leakage current. The setting of the support bar 10 not only enhances the stability of the structure, but also further isolates the electromagnetic coupling between the primary winding 4 and the shielding copper layer 3 through its non-conductive properties. The application of the insulating paper layer 5 provides additional electrical insulation protection between the layers, further reduces the possibility of leakage current, enhances the overall performance and safety of the transformer, enables the transformer to operate stably in a high voltage environment, while maintaining a low leakage current, and improves the reliability and long-term durability of the system.

[0047] The secondary winding 2 is wound on the skeleton 1 from the secondary winding starting line 21 to the secondary winding ending line 22, and the shielding copper layer 3 is led out from the shielding copper outlet terminal 31. The primary winding 4 is wound on the outer layer of the support bar 10, between the support bar and the primary winding interlayer insulation layer 7, from the primary winding starting line 41 to the primary winding ending line 42.

[0048] In other embodiments, the stay 10 may be made of other non-conductive and high temperature resistant materials, such as ceramics or insulating synthetic materials, to adapt to different environments and application requirements.

[0049] In a possible implementation manner, a support block 11 is provided on one side of the transformer and is located between the secondary winding 2 and the shielding copper layer 3. Two or more support blocks 11 are provided, and the thickness of the support blocks 11 is 8-10 mm.

[0050] The setting of the support block 11 enhances the overall stability of the transformer structure and its mechanical strength, while improving the electromagnetic shielding effect; the support block 11 is located between the secondary winding 2 and the shielding copper layer 3, which can further isolate electromagnetic interference and ensure the clean and stable current transmission. The thickness of the support block 11 is selected to be 8-10mm to optimize its structural support capacity while not excessively affecting the size and weight of the transformer, thereby improving the reliability and stability of the transformer in a complex electromagnetic environment.

[0051] The support block 11 may be made of different non-conductive materials, such as high-performance plastics, composite materials or ceramics, to adapt to different operating environments and cost requirements.

[0052] In a possible implementation, the primary winding 4 and the secondary winding 2 are wound and formed by conductive materials; the shielding copper layer 3 is made of conductive materials. In this embodiment, the primary winding 4 and the secondary winding 2 are made of conductive materials, such as copper or aluminum, which ensure the effective transmission of electric energy and the minimum energy loss through their excellent conductivity; the shielding copper layer 3 is also made of conductive materials, which provides effective electromagnetic shielding, reduces the influence of external electromagnetic interference, and protects internal components from external electromagnetic fields, thereby increasing the transformer's resistance to electromagnetic interference and ensuring the stability and reliability of current transmission.

[0053] The primary winding 4 and the secondary winding 2 can be made of materials with different resistivities, such as high-temperature superconducting materials or silver-plated copper wire, to adapt to specific application requirements and operating environments; the shielding copper layer 3 can also be replaced with other materials with strong electrical conductivity but lower cost, such as aluminum, to balance performance and cost.

[0054] In a possible implementation, the material of the support bar 10 is a non-conductive and high temperature resistant plastic or ceramic material. In this embodiment, the support bar 10 is made of a non-conductive and high temperature resistant material, such as a specific type of plastic or ceramic, to provide insulation isolation while ensuring performance stability and electrical safety under high temperature conditions.

[0055] Using non-conductive and high-temperature resistant materials such as plastic or ceramic as the support bar 10 can improve the temperature resistance and durability of the transformer while taking into account the electrical isolation performance, and enhance the transformer's ability to operate stably under different temperature conditions, making it suitable for high-load or high-temperature environments.

[0056] In other embodiments, the struts 10 may also be made of other high-performance composite materials, such as glass fiber reinforced plastic or carbon fiber materials, to provide higher mechanical strength and better thermal stability; at the same time, according to the specific application environment and cost considerations, struts 10 of different thicknesses and shapes are selected to optimize the structural design and performance.

[0057] In a possible implementation, the conductor material of the primary winding 4 and the secondary winding 2 is copper wire with high electrical conductivity and heat resistance. The primary winding 4 and the secondary winding 2 use copper wire with high electrical conductivity and good heat resistance. The high electrical conductivity of the copper wire ensures the efficiency of current transmission and reduces energy loss. At the same time, the heat resistance of the copper wire ensures that the winding will not be damaged due to overheating under long-term operation or high-load conditions, thereby ensuring the stability and safety of the transformer.

[0058] As an alternative implementation, other types of wire materials, such as silver or aluminum, can be used according to specific application requirements. According to the specific requirements of cost and application scenarios, selecting the appropriate material can achieve the best balance between performance and cost.

[0059] In a possible implementation manner, the edge of the shielding copper layer 3 is rounded to avoid excessive electric field concentration at sharp corners.

[0060] In this embodiment, the edges of the shielding copper layer 3 are rounded to reduce the concentration of the electric field at sharp angles, improve tip discharge, and thus reduce the risk of arcing or discharge, improve the insulation performance of the transformer, further reduce leakage and loss, and improve the electrical safety and stability of the transformer.

[0061] In other embodiments, the edge processing of the shielding copper layer 3 may adopt different technical means, such as using a special coating or adding additional insulating material to cover the edge, so as to further enhance its safety and durability.

[0062] In a possible implementation manner, the support block 11 has a thickness of 8 mm.

[0063] The transformer also includes two temperature switches 12 disposed between the secondary winding 2 and the shielding copper layer 3, for cutting off the transformer current when the temperature exceeds a set value, such as 140°C or 160°C.

[0064] The transformer of the utility model effectively reduces the generation of leakage current and enhances the safety and stability of the equipment by providing an insulating layer and a support bar 10; the provision of the support block 11 further cuts off the leakage path of the current; the rounding of the sharp corners of the shielding copper layer 3 improves the tip discharge, thereby achieving the purpose of optimizing the electromagnetic field distribution and reducing the leakage current, thereby improving the safety and stability of the transformer.

[0065] Finally, it should be noted that: the various embodiments in this specification are described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the various embodiments can be referenced to each other.

[0066] The above embodiments are only used to illustrate the technical solution of the present application rather than to limit it. Although the present application has been described in detail with reference to the preferred embodiments, ordinary technicians in the relevant field should understand that the specific implementation methods of the present application can still be modified or some technical features can be replaced by equivalents without departing from the spirit of the technical solution of the present application, which should be included in the scope of the technical solution requested for protection in the present application.

Claims

1. A transformer for reducing leakage current, characterized in that: include: A transformer frame (1) made of an electrically insulating material; A secondary winding (2), a shielding copper layer (3) and a primary winding (4) wound on a frame (1), wherein the secondary winding (2), the shielding copper layer (3) and the primary winding (4) are arranged in layers from inside to outside in the order of secondary winding (2), shielding copper layer (3) and primary winding (4); Four or more stays (10) are arranged between the shielding copper layer (3) and the primary winding (4), the stays (10) have a thickness of 3 mm, and one or more stays (10) are respectively arranged in four directions of the transformer skeleton (1); Insulating paper layers are stacked between the secondary winding (2) and the shielding copper layer (3), between the shielding copper layer (3) and the stay (10), between the stay (10) and the primary winding (4), on the periphery of the primary winding (4), and between each layer of the secondary winding (2) and the primary winding (4); The skeleton (1) comprises a layer of insulating paper with a thickness of 0.5 mm, two layers of insulating paper with a thickness of 0.14 mm, and two layers of insulating paper with a thickness of 0.24 mm. A layer of 0.14 mm thick insulating paper is provided between each layer of the secondary winding (2); Three layers of 0.14 mm thick insulating paper are arranged between the secondary winding (2) and the shielding copper layer (3); Three layers of 0.14 mm thick insulating paper are arranged between the shielding copper layer (3) and the support bar (10); Two layers of 0.24 mm thick insulating paper are arranged between the stay (10) and the primary winding (4); A layer of 0.14 mm thick insulating paper is arranged between each layer of the primary winding (4); Two layers of 0.24 mm thick insulating paper are arranged outside the primary winding (4).

2. The transformer according to claim 1, characterized in that: It also includes a support block (11) arranged on one side of the transformer and located between the secondary winding (2) and the shielding copper layer (3), wherein two or more support blocks (11) are provided and the thickness of the support blocks is 8-10 mm.

3. The transformer according to claim 2, characterized in that The primary winding (4) and the secondary winding (2) are formed by winding an electrically conductive material; and the shielding copper layer (3) is made of an electrically conductive material.

4. The transformer according to claim 3, characterized in that The support bar (10) is made of non-conductive and high-temperature resistant plastic or ceramic material.

5. The transformer according to claim 4, characterized in that The conductor material of the primary winding (4) and the secondary winding (2) is copper wire with high electrical conductivity and heat resistance.

6. The transformer according to claim 5, characterized in that The edges of the shielding copper layer (3) are rounded to avoid excessive electric field concentration at sharp corners.

7. The transformer according to claim 6, characterized in that The number of the support blocks (11) is two, and the thickness of the support blocks is 8 mm; three support bars (10) are respectively arranged on the four directions of the transformer skeleton.

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