Flat copper wire transformer for power module
By using flat copper wire to wind the primary and secondary winding coils of the transformer, the problem of excessive volume of the traditional transformer is solved, reducing the transformer volume and cost reduction, while improving the current carrying capacity and reducing heating.
Patent Information
- Application Number
- CN202421374296.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-06-15
- Publication Date
- 2025-05-27
- Estimated Expiration
- 2034-06-15
AI Technical Summary
Traditional transformer windings are wound with enameled wire, which leads to an increase in the volume of the frame, which in turn leads to an increase in the volume of the transformer, making it difficult to meet the high requirements of electronic equipment for power supply volume and power density.
The primary and secondary winding coils are wound with flat copper wire, which improves the utilization rate of the frame winding window through rectangular cross-section, reduces the frame volume, and realizes a top-down separation design through insulating gaskets and plug-in designs, reducing costs.
Effectively reduce the volume of the transformer, improve the utilization rate of the skeleton winding window, reduce costs, and the flat copper wire withstands large current and generates small heat.
Smart Images
Figure CN222914529U_ABST
Abstract
Description
Technical Field
[0001] The present application relates to the technical field of transformers, and particularly to a flat copper wire transformer for a power module. Background Art
[0002] With the development of electronic devices, their power is increasing while their volume is decreasing, and higher requirements are imposed on the volume and power density of power supplies. The transformer is the component with the largest volume in the power supply, and its size limits the size of the power supply.
[0003] The windings of traditional transformers are wound with enameled wires, which are in the form of thin copper wires for the inner and outer windings. Even when tightly arranged, there will be gaps in this winding method, resulting in an increase in the volume of the bobbin, and further an increase in the volume of the transformer. Therefore, further improvement is needed. Summary of the Utility Model
[0004] In order to reduce the volume of the transformer, the present application provides a flat copper wire transformer for a power module.
[0005] The flat copper wire transformer for a power module provided by the present application adopts the following technical solutions:
[0006] A flat copper wire transformer for a power module includes a bobbin, a primary winding coil sleeved on the bobbin, a secondary winding coil sleeved on the bobbin, and a magnetic core locked to the primary winding coil and the secondary winding coil. The primary winding coil and the secondary winding coil are coaxial and arranged vertically, and both the primary winding coil and the secondary winding coil are wound with flat copper wires.
[0007] By adopting the above technical solutions, both the primary winding coil and the secondary winding coil are wound with flat copper wires, and their cross-sections are rectangular. Compared with round wires, the utilization rate of the winding window of the bobbin can be greatly improved, or the volume of the bobbin can be effectively reduced under the same number of turns, thereby reducing the volume of the transformer. In addition, the tightly wound flat copper wire can withstand large currents and generate less heat.
[0008] Preferably, the bobbin includes a mounting base and a plug post protruding and fixed to the mounting base. Both the primary winding coil and the secondary winding coil are sleeved on the plug post, and an insulating gasket is sleeved on the plug post and located between the primary winding coil and the secondary winding coil.
[0009] By adopting the above technical solution, the insertion post provides a sleeving carrier for the primary winding coil and the secondary winding coil. The insulating gasket is located between the primary winding coil and the secondary winding coil to prevent the direct contact between the primary winding coil and the secondary winding coil, so that the primary winding coil and the secondary winding coil are designed in an up-and-down separated manner. In addition, primary winding coils and secondary winding coils with different numbers of turns can be installed in the same middle insertion post as needed, reducing costs. Since the height of the primary winding coil / secondary winding coil is reduced due to the decrease in the number of turns of the winding coil, insulating gaskets with different thicknesses can be replaced between the primary winding coil and the secondary winding coil to make up for the loss in height.
[0010] Preferably, wiring pins are arranged on both sides of the mounting base. The wiring ends of the primary winding coil and the secondary winding coil are respectively located on both sides of the mounting base and are correspondingly electrically connected to the wiring pins.
[0011] By adopting the above technical solution, the wiring ends of the primary winding coil and the secondary winding coil are respectively located on both sides of the mounting base, which is convenient for later installation and also reduces the interference between the primary winding coil and the secondary winding coil.
[0012] Preferably, two insertion openings are respectively formed through the mounting base on both sides of the insertion post. The magnetic core includes a lower magnetic block and an upper magnetic block. Extension posts are integrally and convexly fixed at both ends of the upper magnetic block and the lower magnetic block. The extension post of the lower magnetic block is inserted into the insertion opening, the upper magnetic block is located above the insertion post, and the extension post of the upper magnetic block abuts against the extension post of the lower magnetic block. The upper magnetic block and the lower magnetic block are fixed by gluing.
[0013] By adopting the above technical solution, when installing the transformer, after sleeving the primary winding coil and the secondary winding coil on the insertion post, then insert the extension post of the lower magnetic block into the insertion opening, and then fix the upper magnetic block and the lower magnetic block by gluing to realize the locking of the upper magnetic block and the lower magnetic block to the primary winding coil and the secondary winding coil.
[0014] Preferably, a limiting hole extending axially through the upper end surface of the insertion post to the lower end surface of the mounting base is formed, and limiting posts inserted into the limiting hole are integrally and convexly fixed on both the upper magnetic block and the lower magnetic block.
[0015] By adopting the above technical solution, the addition of the limiting hole and the limiting post effectively reduces the possibility of relative sliding between the upper magnetic block and the lower magnetic block.
[0016] Preferably, a sunk groove is formed on the lower end surface of the mounting base, the insertion opening is formed on the bottom wall of the sunk groove, and the lower magnetic block is embedded in the sunk groove.
[0017] By adopting the above technical solution, the lower magnetic block is embedded in the sunk groove, effectively reducing the possibility of the lower magnetic block protruding from the mounting base.
[0018] Preferably, a positioning rod is integrally and convexly fixed to the lower end surface of the extension column of the upper magnetic block, and a positioning hole for inserting the positioning rod is provided on the upper end surface of the extension column of the lower magnetic block.
[0019] By adopting the above technical solution, the positioning rod and the positioning hole are added, so as to realize the positioning plug-in fit of the extension columns of the upper magnetic block and the lower magnetic block, effectively reducing the possibility of relative sliding between the upper magnetic block and the lower magnetic block, and facilitating the subsequent bonding and fixing of the upper magnetic block and the lower magnetic block.
[0020] Preferably, an insulating film or an insulating coating is provided on the outer wall of the flat copper wire.
[0021] By adopting the above technical solution, an insulating film or an insulating coating is provided on the outer wall of the flat copper wire, improving the anti-interference ability of the primary winding coil and the secondary winding coil.
[0022] In summary, the utility model has the following beneficial effects:
[0023] 1. Both the primary winding coil and the secondary winding coil are wound with flat copper wires, and their cross-sections are rectangular. Compared with round wires, the utilization rate of the winding window of the bobbin can be greatly improved, or the volume of the bobbin can be effectively reduced under the same number of turns, thereby reducing the volume of the transformer. In addition, the tightly wound flat copper wire can withstand large currents and generate less heat;
[0024] 2. The wiring ends of the primary winding coil and the secondary winding coil are respectively located on both sides of the mounting base, which is convenient for later installation and also reduces the interference between the primary winding coil and the secondary winding coil;
[0025] 3. The limiting holes and the limiting columns are added, effectively reducing the possibility of relative sliding between the upper magnetic block and the lower magnetic block. BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Figure 1 is a schematic diagram of the overall structure of a flat copper wire transformer for a power module in Embodiment 1;
[0027] Figure 2 is a schematic diagram of the structure of the bobbin in Embodiment 1;
[0028] Figure 3 is a schematic diagram of the sunk groove structure of the mounting base in Embodiment 1;
[0029] Figure 4 is a schematic diagram of the structure of the magnetic core and the bobbin in Embodiment 1;
[0030] Figure 5 is a schematic diagram of the structure of the lower magnetic block and the upper magnetic block in Embodiment 2;
[0031] Figure 6 is a schematic diagram of the connection structure of the lower insertion column and the insulating gasket in Embodiment 3.
[0032] In the figure, 1 is the skeleton; 11 is the mounting base; 12 is the insertion post; 13 is the counterbore; 14 is the insertion interface; 15 is the wiring pin; 16 is the limiting hole; 2 is the primary winding coil; 3 is the secondary winding coil; 4 is the magnetic core; 41 is the lower magnetic block; 42 is the upper magnetic block; 43 is the extension post; 44 is the limiting post; 45 is the positioning rod; 46 is the positioning hole; 5 is the insulating gasket. Specific implementation mode
[0033] The following will further elaborate on this application in conjunction with the attached Figure 1-6 drawings.
[0034] Embodiment 1:
[0035] An embodiment of this application discloses a flat copper wire transformer for a power module. Referring to Figure 1 the figures, it includes a skeleton 1, a primary winding coil 2, a secondary winding coil 3, and a magnetic core 4. The primary winding coil 2 and the secondary winding coil 3 are both sleeved on the skeleton 1, and the magnetic core 4 is locked to the primary winding coil 2 and the secondary winding coil 3. Both the primary winding coil 2 and the secondary winding coil 3 are wound with flat copper wires. The cross-section of the flat copper wire is rectangular, and an insulating film or insulating coating is provided on the outer wall of the flat copper wire. In this embodiment, a polyurethane resin coating is applied to the outer wall of the flat copper wire.
[0036] Referring to Figure 2 and Figure 3 the figures, the skeleton 1 includes a mounting base 11 and an insertion post 12 protruding and fixed on the upper end surface of the mounting base 11. A counterbore 13 is opened on the lower end surface of the mounting base 11, and two insertion interfaces 14 are respectively opened through the upper end surface of the mounting base 11 on both sides of the insertion post 12. The insertion interfaces 14 communicate with the counterbore 13. Wiring pins 15 are fixedly connected to both sides of the mounting base 11. There are multiple wiring pins 15 and they are distributed along the length direction of the mounting base 11.
[0037] The insertion post 12 is a cylinder, and a limiting hole 16 extending to the lower end surface of the mounting base 11 is axially penetrated through the upper end surface of the insertion post 12. Both the primary winding coil 2 and the secondary winding coil 3 are coaxially sleeved on the insertion post 12, and the primary winding coil 2 and the secondary winding coil 3 are arranged vertically. The wiring ends of the primary winding coil 2 and the wiring ends of the secondary winding coil 3 are respectively located on both sides of the mounting base 11 and are correspondingly electrically connected to the wiring pins 15. Insulating gaskets 5 are sleeved on the insertion post 12 above the primary winding coil 2 and above the secondary winding coil 3 respectively.
[0038] Referring to Figure 2 and Figure 4, the magnetic core 4 includes a lower magnetic block 41 embedded in the sinking groove 13 and an upper magnetic block 42 located above the insertion post 12. At both lower end faces of the upper magnetic block 42 and both upper end faces of the lower magnetic block 41, extension posts 43 are integrally and convexly fixed. The two extension posts 43 on the same magnetic block are respectively located on both sides of the primary winding coil 2 / secondary winding coil 3. The extension post 43 of the lower magnetic block 41 is inserted into the insertion interface 14, and the extension post 43 of the upper magnetic block 42 abuts against the extension post 43 of the lower magnetic block 41. At the middle of the lower end face of the upper magnetic block 42 and the middle of the upper end face of the lower magnetic block 41, limit posts 44 inserted into the limit holes 16 are integrally and convexly fixed. The upper magnetic block 42 and the lower magnetic block 41 are fixed by gluing. Specifically, the upper magnetic block 42 and the lower magnetic block 41 are fixed by winding and binding an insulating tape.
[0039] The implementation principle of a flat copper wire transformer for a power module in an embodiment of the present application is as follows: both the primary winding coil 2 and the secondary winding coil 3 are wound with flat copper wires, and their cross-sections are rectangular, which greatly improves the utilization rate of the winding window of the bobbin 1, or effectively reduces the volume of the bobbin 1 under the condition of the same number of turns, thereby reducing the volume of the transformer. In addition, the tightly wound flat copper wires can withstand large currents and generate less heat.
[0040] Embodiment 2:
[0041] The difference from Embodiment 1 is that, referring to Figure 5 , a positioning rod 45 is convexly fixed on the lower end face of the extension post 43 of the upper magnetic block 42, and a positioning hole 46 for inserting the positioning rod 45 is opened on the upper end face of the extension post 43 of the lower magnetic block 41. The positioning and plugging cooperation of the extension posts 43 of the upper magnetic block 42 and the lower magnetic block 41 is realized, which effectively reduces the possibility of relative slippage between the upper magnetic block 42 and the lower magnetic block 41, and is convenient for subsequent tape bundling and fixing of the upper magnetic block 42 and the lower magnetic block 41.
[0042] Embodiment 3:
[0043] The difference from Embodiment 1 is that, referring to Figure 6 , the outer peripheral wall of the insertion post 12 has an external thread, and the inner hole of the insulating gasket 5 is a threaded hole threadedly connected to the external thread, which is convenient for rotating and adjusting the height of the insulating gasket 5 according to the height of the primary winding coil 2 / secondary winding coil 3, without the need to replace insulating gaskets 5 of different thicknesses.
[0044] The above are all preferred embodiments of the present application. The protection scope of the present application is not limited accordingly. Therefore, all equivalent changes made according to the structure, shape, and principle of the present application should be covered within the protection scope of the present application.
Claims
1. A flat copper wire transformer for a power module, characterized in that: The invention comprises a frame (1), a primary winding coil (2) sleeved on the frame (1), a secondary winding coil (3) sleeved on the frame (1), and a magnetic core (4) locked to the primary winding coil (2) and the secondary winding coil (3), wherein the primary winding coil (2) and the secondary winding coil (3) are coaxial and arranged in an upper and lower distribution, and the primary winding coil (2) and the secondary winding coil (3) are both wound by flat copper wire; the frame (1) comprises a mounting seat (11) and a plug post (12) protruding and fixed on the mounting seat (11), the primary winding coil (2) and the secondary winding coil (3) are both sleeved on the plug post (12), and the plug post (12) is sleeved with an insulating gasket (5) located between the primary winding coil (2) and the secondary winding coil (3); the mounting seat (11) having two insertion ports (14) respectively located on both sides of the insertion column (12), the magnetic core (4) comprising a lower magnetic block (41) and an upper magnetic block (42), both ends of the upper magnetic block (42) and the lower magnetic block (41) are integrally protruded and fixed with extension columns (43), the extension column (43) of the lower magnetic block (41) is inserted into the insertion port (14), the upper magnetic block (42) is located above the insertion column (12), the extension column (43) of the upper magnetic block (42) abuts against the extension column (43) of the lower magnetic block (41), and the upper magnetic block (42) and the lower magnetic block (41) are fixed by gluing; the lower end surface of the mounting seat (11) is provided with a recessed groove (13), the insertion port (14) is provided on the bottom wall of the recessed groove (13), and the lower magnetic block (41) is embedded in the recessed groove (13).
2. The flat copper wire transformer for a power module according to claim 1, characterized in that: Wiring pins (15) are provided on both sides of the mounting seat (11); the wiring terminals of the primary winding coil (2) and the wiring terminals of the secondary winding coil (3) are respectively located on both sides of the mounting seat (11) and are electrically connected to the wiring pins (15) accordingly.
3. The flat copper wire transformer for a power module according to claim 1, characterized in that: The upper end surface of the plug post (12) is axially penetrated with a limiting hole (16) extending to the lower end surface of the mounting seat (11), and the upper magnetic block (42) and the lower magnetic block (41) are integrally protruded and fixed with a limiting post (44) inserted in the limiting hole (16).
4. The flat copper wire transformer for a power module according to claim 1, characterized in that: A positioning rod (45) is integrally protruded and fixed on the lower end surface of the extension column (43) of the upper magnetic block (42), and a positioning hole (46) for inserting the positioning rod (45) is provided on the upper end surface of the extension column (43) of the lower magnetic block (41).
5. The flat copper wire transformer for a power module according to claim 1, characterized in that: The outer wall of the flat copper wire is provided with an insulating film or an insulating coating.