Horizontal transformer

Abstract

The utility model relates to a horizontal transformer, a winding comprises a coil winding and a conductor foil winding, the conductor foil winding comprises a first conductor foil and a second conductor foil which are vertically staggered and laminated, the peripheral surfaces of the first conductor foil and the second conductor foil are respectively wound with a second insulating layer, and the two ends of the first conductor foil and the two ends of the second conductor foil extend out of the second insulating layer; two ends of the first conductor foil and the second conductor foil are respectively provided with a first welding part and a second welding part; efficiency is improved, magnetic loss is reduced, heat dissipation direct blowing is facilitated, and heat dissipation efficiency is improved.

Description

Technical Field

[0001] The utility model relates to the technical field of horizontal transformers, in particular to a horizontal transformer. Background Art

[0002] like Figures 1 to 4 As shown, the existing LLC transformer is generally a frameless winding transformer, which includes an upper magnetic core 11, a lower magnetic core 12, a red copper tin plate, a vertical plate 13, a bottom plate 14 and a winding;

[0003] The upper magnetic core 11 and the lower magnetic core 12 are arranged opposite to each other and connected, and the vertical plate 13 and the bottom plate 14 form an L-shaped structure. The vertical plate 13 is located behind the upper magnetic core 11 and the lower magnetic core 12, and the upper magnetic core 11 and the lower magnetic core 12 are both arranged above the bottom plate 14.

[0004] The three tin-plated copper plates are arranged at vertical intervals behind the vertical plate 13, and the lower end of each tin-plated copper plate passes through the bottom plate 14 and extends out of the lower end surface of the bottom plate 14 to form the wire drawing end of the secondary winding, which are C wire drawing end, D wire drawing end and E wire drawing end from right to left.

[0005] The winding includes a first insulating gasket, an N7 coil, a second insulating gasket, an N6 coil, a third insulating gasket, an N5 coil, a fourth insulating gasket, an N4 coil, a fifth insulating gasket, an N3 coil, a sixth insulating gasket, an N2 coil, a seventh insulating gasket, an N1 coil and an eighth insulating gasket which are stacked in sequence from top to bottom; wherein the N2 coil, the N4 coil and the N6 coil are all wire-wrapped coils and together form a primary winding, the primary winding having an A drawing end and a B drawing end, and the two ends of the N2 coil, the N4 coil and the N6 coil pass through the bottom plate 14 and are respectively welded to the A drawing end and the B drawing end.

[0006] The N7 coil, the N5 coil, the N3 coil and the N1 coil form a secondary winding. The N7 coil, the N5 coil, the N3 coil and the N1 coil are all flat coils, and the flat coils have a first lead end and a second lead end.

[0007] As shown in the figure, three red copper tin-plated plates are defined from left to right as a first red copper tin-plated plate 151, a second red copper tin-plated plate 152 and a third red copper tin-plated plate 153, and the heights of the first red copper tin-plated plate 151, the second red copper tin-plated plate 152 and the third red copper tin-plated plate 153 gradually increase from right to left;

[0008] The first lead ends of the N7 coil and the N5 coil sequentially pass through the vertical plate 13 and the first red copper tin plate 151, then extend out of the first red copper tin plate 151, and the first lead ends of the N7 coil and the N5 coil are welded to the first red copper tin plate 151; the second lead ends of the N7 coil and the N5 coil sequentially pass through the vertical plate 13 and the second red copper tin plate 152, then extend out of the second red copper tin plate 152, and the second lead ends of the N7 coil and the N5 coil are welded to the second red copper tin plate 152;

[0009] The first lead ends of the N3 coil and the N1 coil pass through the vertical plate 13 and the second red copper tinplate 152 in sequence, then extend out of the second red copper tinplate 152, and the first lead ends of the N3 coil and the N1 coil are welded to the second red copper tinplate 152; the second lead ends of the N3 coil and the N1 coil pass through the vertical plate 13 and the third red copper tinplate 153 in sequence, then extend out of the third red copper tinplate 153, and the second lead ends of the N3 coil and the N1 coil are welded to the third red copper tinplate 153.

[0010] However, the structure of the above transformer has the following defects:

[0011] 1. Flat coils need to be molded;

[0012] 2. The N7 coil, N5 coil, N3 coil and N1 coil need to be connected in parallel and then welded to the corresponding red copper tin-plated plates. Once a large current appears, the red copper tin-plated plates will cause losses and reduce efficiency; and the entire process cost is high.

[0013] Therefore, in the utility model patent application, the applicant carefully studied the horizontal transformer to solve the above problems. Utility Model Content

[0014] The utility model aims at solving the above-mentioned deficiencies in the prior art, and its main purpose is to provide a horizontal transformer, which improves efficiency, reduces magnetic loss, and facilitates direct heat dissipation, thereby improving heat dissipation efficiency.

[0015] In order to achieve the above-mentioned purpose, the utility model adopts the following technical solutions:

[0016] A horizontal transformer comprises a frame, a first magnetic core, a second magnetic core and a winding; the frame has a winding shaft, the first magnetic core is arranged in front of the frame and partially embedded in the frame, the second magnetic core is directly opposite to the first magnetic core, the second magnetic core is arranged behind the frame and partially embedded in the frame, and the winding is wound on the winding shaft and surrounds the first magnetic core and the second magnetic core embedded in the frame;

[0017] The winding comprises a wire-wrapped winding and a conductor foil winding, wherein the wire-wrapped winding is wound on a winding shaft and surrounds the first magnetic core and the second magnetic core embedded in the main body, wherein the wire-wrapped winding has a first lead end and a second lead end, wherein the first lead end and the second lead end both extend out of the frame, and a first insulating layer is wound around the outer peripheral surface of the wire-wrapped winding;

[0018] The conductor foil winding is wound on the first insulating layer, and the conductor foil winding includes a first conductor foil and a second conductor foil which are stacked and staggered up and down, the outer circumferential surfaces of the first conductor foil and the second conductor foil are both wound with the second insulating layer, and both ends of the first conductor foil and the second conductor foil extend out of the second insulating layer, and the first conductor foil and the second conductor foil have a first welding portion and a second welding portion at both ends respectively;

[0019] The first conductor foil and the second conductor foil are both bendable Z-shaped conductor foils, the Z-shaped conductor foil comprises a longitudinal portion, a first transverse portion and a second transverse portion, two ends of the first transverse portion are respectively connected to the longitudinal portion and the first welding portion, and two ends of the second transverse portion are respectively connected to the longitudinal portion and the second welding portion;

[0020] The first transverse portion of the first conductor foil is simultaneously stacked on the front section of the longitudinal portion of the second conductor foil and part of the first transverse portion, and the first welding portion of the first conductor foil is located inside the first welding portion of the second conductor foil;

[0021] The second transverse portion of the second conductor foil is simultaneously stacked on the rear section of the longitudinal portion of the first conductor foil and part of the second transverse portion, and the second welding portion of the first conductor foil is located outside the second welding portion of the second conductor foil;

[0022] The first transverse portion of the first conductor foil, the front section of the longitudinal portion of the second conductor foil and the first transverse portion are wound together along one direction on the outer circumference of a portion of the first insulating layer;

[0023] The second transverse portion of the second conductor foil, the rear section of the longitudinal portion of the first conductor foil and the second transverse portion are wound together along another direction on the outer circumference of another portion of the first insulating layer.

[0024] As a preferred solution, the first conductor foil and the second conductor foil have the same structure.

[0025] As a preferred solution, a circuit board is also included, and the first lead end, the second lead, and the first welding portion and the second welding portion of the first conductor foil and the second conductor foil are all welded to the circuit board and extend out of the same end surface of the circuit board.

[0026] As a preferred solution, it further comprises a core wrapping tape, wherein the core wrapping tape wraps the first magnetic core and the second magnetic core.

[0027] Compared with the prior art, the utility model has obvious advantages and beneficial effects. Specifically, it mainly improves the secondary winding, that is, the first conductor foil and the second conductor foil are stacked up and down in an offset manner to improve efficiency and reduce magnetic loss. Moreover, the first conductor foil and the second conductor foil are used to facilitate direct heat dissipation and improve heat dissipation efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 is a side view of the prior art;

[0029] Figure 2 It is a rear view of the prior art;

[0030] Figure 3 It is a schematic diagram of a coil of the prior art;

[0031] Figure 4 It is a schematic diagram of the exploded structure of an embodiment of the utility model in a top view; (the first insulating layer and the second insulating layer are not shown);

[0032] Figure 5 It is a schematic diagram of the cross-sectional structure of an embodiment of the utility model;

[0033] Figure 6 It is a schematic diagram of the first conductor foil and the second conductor foil in an un-stacked state according to an embodiment of the utility model;

[0034] Figure 7 It is a schematic diagram of a first conductor foil and a second conductor foil in a stacked state according to an embodiment of the present utility model.

[0035] Description of Figure Numbers:

[0036] 11. Upper magnetic core 12. Lower magnetic core

[0037] 13. Vertical plate 14. Bottom plate

[0038] 151. The first red copper tinplate

[0039] 152. Second red copper tin plate

[0040] 153. The third red copper tin plate

[0041] 21. Frame 211. Winding shaft

[0042] 22. first magnetic core 23. second magnetic core 24. circuit board

[0043] 31. Wire winding 32. First insulation layer

[0044] 401, first conductor foil 402, second conductor foil

[0045] 403, first welding part 404, second welding part

[0046] 41. First transverse portion

[0047] 42. longitudinal portion 43. second transverse portion

[0048] 44. Second insulating layer. DETAILED DESCRIPTION

[0049] The utility model is further described below in conjunction with the accompanying drawings and specific implementation methods.

[0050] like Figures 4 to 7 As shown, a horizontal transformer includes a frame 21, a first magnetic core 22, a second magnetic core 23, a winding, a circuit board 24 and a magnetic core wrapping tape.

[0051] The skeleton 21 has a winding axis. Preferably, the first magnetic core 22 and the second magnetic core 23 are iron cores. The first magnetic core 22 is arranged in front of the skeleton 21 and partially embedded in the skeleton 21. The second magnetic core 23 is directly opposite to the first magnetic core 22, and the second magnetic core 23 is arranged behind the skeleton 21 and partially embedded in the skeleton 21. The magnetic core wrapping tape wraps the first magnetic core 22 and the second magnetic core 23 to form the skeleton 21, the winding, the first magnetic core 22 and the second magnetic core 23 into a whole.

[0052] The winding is wound on the bobbin and surrounds the first magnetic core 22 and the second magnetic core 23 embedded in the frame 21.

[0053] The winding includes a wire-wrapped winding 31 and a conductor foil winding. The wire-wrapped winding 31 is wound on a winding shaft and surrounds the first magnetic core 22 and the second magnetic core 23 embedded in the main body. The wire-wrapped winding 31 has a first lead end and a second lead end. The first lead end and the second lead end both extend out of the frame 21. The outer peripheral surface of the wire-wrapped winding 31 is wrapped with a first insulating layer 32.

[0054] The conductor foil winding is wound on the first insulating layer 32, and includes a first conductor foil 401 and a second conductor foil 402 which are stacked and staggered up and down. Preferably, the first conductor foil 401 and the second conductor foil 402 have the same structure.

[0055] In this embodiment, the first conductor foil 401 and the second conductor foil 402 are both made of copper foil, because copper foil has good electrical conductivity. Preferably, the copper foil is made of red copper. In actual operation, aluminum foil or other materials with good electrical conductivity can also be used according to actual needs, which is not limited here. In addition, the thickness of the first conductor foil 401 and the second conductor foil 402 needs to be selected according to the current size of the load.

[0056] The outer circumferential surfaces of the first conductor foil 401 and the second conductor foil 402 are both wrapped with a second insulating layer 44, and both ends of the first conductor foil 401 and the second conductor foil 402 extend out of the second insulating layer 44. In this embodiment, the first insulating layer 32 and the second insulating layer 44 are both insulating tape layers. The first conductor foil 401 and the second conductor foil 402 have a first welding portion 403 and a second welding portion 404 at both ends, respectively.

[0057] The first lead end, the second lead, and the first welding portion 403 and the second welding portion 404 of the first conductor foil 401 and the second conductor foil 402 are all welded to the circuit board 24 and extend out of the same end surface of the circuit board 24 .

[0058] The first conductor foil 401 and the second conductor foil 402 are both bendable Z-shaped conductor foils, and the Z-shaped conductor foils include a longitudinal portion 42, a first transverse portion 41, and a second transverse portion 43. The two ends of the first transverse portion 41 are respectively connected to the longitudinal portion 42 and the first welding portion 403, and the two ends of the second transverse portion 43 are respectively connected to the longitudinal portion 42 and the second welding portion 404.

[0059] The first transverse portion 41 of the first conductor foil 401 is stacked on the front section of the longitudinal portion 42 of the second conductor foil 402 and part of the first transverse portion 41, and the first welding portion 403 of the first conductor foil 401 is located inside the first welding portion 403 of the second conductor foil 402;

[0060] The second transverse portion 43 of the second conductor foil 402 is stacked on the rear section of the longitudinal portion 42 of the first conductor foil 401 and part of the second transverse portion 43, and the second welding portion 404 of the first conductor foil 401 is located outside the second welding portion 404 of the second conductor foil 402;

[0061] The first transverse portion 41 of the first conductor foil 401, the front section of the longitudinal portion 42 of the second conductor foil 402 and the first transverse portion 41 are wound together along one direction on the outer circumference of a portion of the first insulating layer 32;

[0062] The second transverse portion 43 of the second conductor foil 402 , the rear section of the longitudinal portion 42 of the first conductor foil 401 , and the second transverse portion 43 are wound together along another direction around the outer circumference of another portion of the first insulating layer 32 .

[0063] A method for manufacturing a horizontal transformer, which is used to manufacture the horizontal transformer, comprises the following steps:

[0064] S1, first prepare the skeleton 21, the first magnetic core 22, the second magnetic core 23, the winding, the first insulating layer 32, the second insulating layer 44, the circuit board 24 and the magnetic core wrapping tape;

[0065] The skeleton 21 has a winding shaft, the winding includes a wire wrapped winding 31 and a conductor foil winding, the wire wrapped winding 31 has a first lead end and a second lead end, the conductor foil winding includes a first conductor foil 401 and a second conductor foil 402, the first conductor foil 401 and the second conductor foil 402 have a first welding portion 403 and a second welding portion 404 at both ends, the first conductor foil 401 and the second conductor foil 402 are both bendable Z-shaped conductor foils, and the Z-shaped conductor foil includes a longitudinal portion 42 and a first transverse portion 41 and a second transverse portion 43 respectively connected to the longitudinal portion 42 in one piece;

[0066] S2, winding the winding wire of the wire package winding 31 layer by layer on the winding shaft to form an N1 coil, and extending the first lead end and the second lead end out of the frame 21;

[0067] S3, winding the first insulating layer 32 around the outer peripheral surface of the wire winding 31;

[0068] S4, the second insulating layer 44 is wrapped around the outer circumferential surfaces of the first conductor foil 401 and the second conductor foil 402, and both ends of the first conductor foil 401 and the second conductor foil 402 extend out of the second insulating layer 44, and the first welding portion 403 and the second welding portion 404 of the first conductor foil 401 and the second conductor foil 402 extend out of the second insulating layer 44;

[0069] S5, stacking the first conductor foil 401 and the second conductor foil 402 in an offset manner, wherein the first transverse portion 41 of the first conductor foil 401 is stacked on the front section of the longitudinal portion 42 of the second conductor foil 402 and part of the first transverse portion 41, and the first welding portion 403 of the first conductor foil 401 is located inside the first welding portion 403 of the second conductor foil 402;

[0070] The second transverse portion 43 of the second conductor foil 402 is stacked on the rear section of the longitudinal portion 42 of the first conductor foil 401 and part of the second transverse portion 43, and the second welding portion 404 of the first conductor foil 401 is located outside the second welding portion 404 of the second conductor foil 402;

[0071] S6, winding the first transverse portion 41 of the first conductor foil 401, the front section of the longitudinal portion 42 of the second conductor foil 402 and the first transverse portion 41 together along one direction on the outer circumference of a portion of the first insulating layer 32, i.e. forming an N2 winding;

[0072] The second transverse portion 43 of the second conductor foil 402, the rear section of the longitudinal portion 42 of the first conductor foil 401 and the second transverse portion 43 are wound together along another direction on the outer periphery of another portion of the first insulating layer 32, that is, the conductor foil winding is wound on the first insulating layer 32;

[0073] S7, firstly, the first magnetic core 22 is arranged in front of the frame 21 and partially embedded in the frame 21, and then the second magnetic core 23 is arranged opposite to the first magnetic core 22, and the second magnetic core 23 is arranged behind the frame 21 and partially embedded in the frame 21, and the winding is made to surround the first magnetic core 22 and the second magnetic core 23 embedded in the frame 21;

[0074] S8, welding the first lead end, the second lead, and the first welding portion 403 and the second welding portion 404 of the first conductor foil 401 and the second conductor foil 402 to the circuit board 24, and extending them out of the same end surface of the circuit board 24;

[0075] S9, wrapping the first magnetic core 22 and the second magnetic core 23 with a core wrapping tape.

[0076] It should be noted that the number of turns of the horizontal transformer obtained by the above-mentioned manufacturing method is:

[0077] N1: N2: N3 = 28: 2: 2, instead of the traditional 14: 1: 1. This design makes the primary turns of the horizontal transformer sufficient, so that the inductance is large, the magnetic loss is small, and it is not easy to saturate. Then, the inductance value is better and the design is more reasonable.

[0078] In this embodiment, the first lead end, the second lead, and the first welding portion 403 and the second welding portion 404 of the first conductor foil 401 and the second conductor foil 402 can be directly welded to the PCB, which reduces conduction loss in high current applications and further improves efficiency.

[0079] In this embodiment, after being installed with the computer motherboard, because the horizontal transformer adopts a horizontal design, its first conductor foil 401 and the second conductor foil 402 are exposed to the outside, so when the fan on the motherboard blows directly to it, it is beneficial to heat dissipation. Moreover, the first conductor foil 401 and the second conductor foil 402 can withstand a larger current. Therefore, the magnetic core of the same volume can produce a higher power and save more money.

[0080] The key points of the utility model design are: it mainly improves the secondary winding, that is, the first conductor foil and the second conductor foil are stacked up and down in an offset manner to improve efficiency and reduce magnetic loss. Moreover, the first conductor foil and the second conductor foil are used to facilitate direct heat dissipation and improve heat dissipation efficiency.

[0081] The above description is only a preferred embodiment of the present invention and does not limit the technical scope of the present invention. Therefore, any minor modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. A horizontal transformer, comprising a frame, a first magnetic core, a second magnetic core and a winding; the frame has a winding shaft, the first magnetic core is arranged in front of the frame and partially embedded in the frame, the second magnetic core is directly opposite to the first magnetic core, the second magnetic core is arranged behind the frame and partially embedded in the frame, the winding is wound on the winding shaft and surrounds the first magnetic core and the second magnetic core embedded in the frame, characterized in that: The winding comprises a wire-wrapped winding and a conductor foil winding, wherein the wire-wrapped winding is wound on a winding shaft and surrounds the first magnetic core and the second magnetic core embedded in the main body, wherein the wire-wrapped winding has a first lead end and a second lead end, wherein the first lead end and the second lead end both extend out of the frame, and a first insulating layer is wound around the outer peripheral surface of the wire-wrapped winding; The conductor foil winding is wound on the first insulating layer, and the conductor foil winding includes a first conductor foil and a second conductor foil which are stacked and staggered up and down, the outer circumferential surfaces of the first conductor foil and the second conductor foil are both wound with the second insulating layer, and both ends of the first conductor foil and the second conductor foil extend out of the second insulating layer, and the first conductor foil and the second conductor foil have a first welding portion and a second welding portion at both ends respectively; The first conductor foil and the second conductor foil are both bendable Z-shaped conductor foils, the Z-shaped conductor foil comprises a longitudinal portion, a first transverse portion and a second transverse portion, two ends of the first transverse portion are respectively connected to the longitudinal portion and the first welding portion, and two ends of the second transverse portion are respectively connected to the longitudinal portion and the second welding portion; The first transverse portion of the first conductor foil is simultaneously stacked on the front section of the longitudinal portion of the second conductor foil and part of the first transverse portion, and the first welding portion of the first conductor foil is located inside the first welding portion of the second conductor foil; The second transverse portion of the second conductor foil is simultaneously stacked on the rear section of the longitudinal portion of the first conductor foil and part of the second transverse portion, and the second welding portion of the first conductor foil is located outside the second welding portion of the second conductor foil; The first transverse portion of the first conductor foil, the front section of the longitudinal portion of the second conductor foil and the first transverse portion are wound together along one direction on the outer circumference of a portion of the first insulating layer; The second transverse portion of the second conductor foil, the rear section of the longitudinal portion of the first conductor foil and the second transverse portion are wound together along another direction on the outer circumference of another portion of the first insulating layer.

2. The horizontal transformer according to claim 1, characterized in that: The first conductor foil and the second conductor foil have the same structure.

3. The horizontal transformer according to claim 1, characterized in that: A circuit board is also included. The first lead end, the second lead, and the first welding parts and the second welding parts of the first conductor foil and the second conductor foil are all welded to the circuit board and extend out of the same end surface of the circuit board.

4. The horizontal transformer according to claim 1, characterized in that: The invention also includes a core wrapping tape, wherein the core wrapping tape wraps the first magnetic core and the second magnetic core.

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