Isolated circuit

Abstract

The utility model provides an isolation type circuit. The isolation type circuit comprises a power factor correction circuit and a resonance conversion circuit. Wherein the resonant conversion circuit comprises a primary circuit, a resonant circuit and a secondary circuit, the resonant circuit comprises a resonant inductor, a resonant capacitor and a transformer, and the transformer comprises a primary winding and a secondary winding. The primary winding and / or the secondary winding comprise / comprises a winding wire, and the winding wire comprises a wire and an insulating layer wrapping the wire. Wherein one side, parallel to the X-axis direction, of the insulating layer is fixed on the lead arranged in the direction parallel to the X-axis direction, then the lead is wound and wrapped in the Y-axis direction perpendicular to the X-axis direction until the number of the insulating layers wrapping the lead is at least three, and the withstand voltage value between the input end and the output end of the isolated circuit ranges from 4000 VAC to 5000 VAC. The isolation type circuit has the advantages of being high in voltage resistance and meeting safety requirements.

Description

Technical Field

[0001] The utility model relates to the technical field of power electronics, and particularly relates to an isolation type circuit. Background Art

[0002] Generally, an inductor element can be added to a transformer to increase the inductance of a switching power supply, so as to adjust the electrical characteristics of the transformer, such as improving the load adaptability and stability of the transformer, enabling it to operate more effectively under different working conditions. In addition, the increase in inductance can reduce the short-circuit current of the transformer, thereby reducing the loss of current in the transformer coil, helping to improve the efficiency of the transformer and reduce energy loss, etc.

[0003] The inventor has learned that the structure of a transformer can increase the distance between the primary winding coil and the secondary winding coil by setting a partition slot between the primary winding coil and the secondary winding coil, so as to replace the setting of an external inductor element. However, the setting of the partition slot will increase the height of the transformer, making this transformer not meet the low-height requirement of a thin transformer.

[0004] In addition, in order to meet safety regulations, most transformers in existing switching power supplies use triple-insulated enameled wire for winding to meet the insulation requirements. Although this method meets the needs of safety regulations, the material cost of triple-insulated enameled wire is relatively high, which is not conducive to reducing production costs; moreover, triple-insulated enameled wire has a relatively high hardness, and it is easy to cause too large a space for the transformer when wound into a winding, which is not conducive to improving the power density of the transformer. At the same time, using triple-insulated enameled wire for winding occupies a relatively large space, making the distance between the primary winding coil and the secondary winding coil of the transformer relatively close, resulting in a relatively low withstand voltage between the input end and the output end of the circuit and being unable to meet the application requirements of high withstand voltage. Another winding method by helically coating an insulating layer learned by the inventor also has the above problems.

[0005] In view of this, the utility model aims at the above existing problems and proposes an isolation type circuit. Content of the Utility Model

[0006] To overcome the above problems, the purpose of the present utility model is to provide an isolated circuit, which includes a power factor correction circuit and a resonant conversion circuit connected in series in sequence. The resonant conversion circuit includes a primary circuit, a resonant circuit, and a secondary circuit connected in series in sequence. The resonant circuit includes a resonant inductor, a resonant capacitor, and a transformer. The transformer includes a primary winding and a secondary winding, and the resonant inductor, the resonant capacitor, and the primary winding are connected in series, and the secondary winding is electrically connected to the secondary circuit. Wherein the primary winding and / or the secondary winding includes a winding, and the winding includes a wire and an insulating layer covering the wire. Wherein, after one side of the insulating layer is fixed to the wire arranged along the X-axis direction parallelly, the wire is wound and covered along the Y-axis direction perpendicular to the X-axis direction until the number of insulating layers of the wire is at least 3 layers, and the withstand voltage value between the input end and the output end of the isolated circuit is 4000VAC to 5000VAC.

[0007] According to one embodiment of the utility model, the power factor correction circuit includes a rectification circuit and a boost circuit connected in series in sequence. The boost circuit includes: a storage inductor, the first end of the storage inductor is electrically connected to the rectification circuit; a first switch, the first power terminal of the first switch is electrically connected to the second end of the storage inductor, and the second power terminal of the first switch is electrically connected to the ground terminal; a diode, the anodic terminal of the diode is electrically connected to the first power terminal of the first switch; and a first output capacitor, the first end of the first output capacitor is electrically connected to the cathodic terminal of the diode, and the second end of the first output capacitor is electrically connected to the ground terminal.

[0008] According to one embodiment of the utility model, the primary circuit includes an inverter circuit, which is electrically connected to the boost circuit. The inverter circuit includes a second switch and a third switch, and the third switch and the second switch are connected in series and electrically connected between the cathodic terminal of the diode and the ground terminal. The secondary circuit includes: a fourth switch, the first power terminal of the fourth switch is electrically connected to the first end of the secondary winding, and the second power terminal of the fourth switch is electrically connected to the negative output terminal of the isolated circuit; a fifth switch, the first power terminal of the fifth switch is electrically connected to the second end of the secondary winding, and the second power terminal of the fifth switch is electrically connected to the negative output terminal of the isolated circuit; and a second output capacitor, which is electrically connected between the positive output terminal and the negative output terminal of the isolated circuit. The secondary winding also has a center tap terminal, which is electrically connected to the positive output terminal of the isolated circuit.

[0009] According to one embodiment of the utility model, the winding includes a plurality of wires, and the plurality of wires are helically twisted at least 33 times within a length of one meter.

[0010] According to one embodiment of the utility model, each of the plurality of wires includes a core wire and a coating. The core wire has a first wire diameter, the plurality of twisted wires have a second wire diameter, the winding has a third wire diameter, and the third wire diameter is smaller than the total wire diameter of the insulation layer covering each of the plurality of wires with at least three layers, and the third wire diameter is smaller than the total wire diameter of the insulation layer helically covering the plurality of wires with at least three layers.

[0011] According to one embodiment of the utility model, the number of strands of the plurality of wires is greater than or equal to 33, and the second wire diameter is at least 0.55 mm.

[0012] According to one embodiment of the utility model, the insulation layer includes insulating tape.

[0013] According to one embodiment of the utility model, there is a spacing distance between the primary winding and the secondary winding.

[0014] According to one embodiment of the utility model, an insulating layer is provided between the spacing distances.

[0015] According to one embodiment of the utility model, the resonant inductor is composed of the leakage inductance formed by the spacing distance or the insulating layer.

[0016] According to one embodiment of the utility model, when the resonant inductor is an externally applied inductive element, the resonant inductor includes the winding.

[0017] The isolated circuit of the present utility model uses a winding that is easy to automate in processing, has at least three layers of insulation layer covered, and the final wire diameter is smaller than that of a known three-layer insulated wire, and has advantages such as high withstand voltage value and compliance with safety regulations. Furthermore, by using a winding with a small final wire diameter, it helps to reduce the volume of the winding group and increase the space between the winding groups. In addition to reducing the overall height of the transformer, it can also achieve the effect of increasing the leakage inductance. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 is a schematic structural diagram of the first embodiment of the winding of the present utility model.

[0019] Figure 2 is Figure 1 a side view of

[0020] Figure 3 is a schematic structural diagram of the second embodiment of the winding of the present utility model.

[0021] Figure 4 is Figure 3 a side view of

[0022] Figure 5 is Figure 1 a flowchart of the method for preparing the winding in

[0023] Figure 6 is Figure 5 the sub - step flowchart of step S12 in

[0024] Figure 7 is Figure 3 the flowchart of the winding preparation method in

[0025] Figure 8 is the schematic structural diagram of the third embodiment of the winding of the present utility model.

[0026] Figure 9 is Figure 1 the schematic cross - sectional view of the winding shown in

[0027] Figure 10 is Figure 8 the schematic cross - sectional view of the winding shown in

[0028] Figure 11 is the cross - sectional view of a single wire in a winding containing multiple wires according to the fourth embodiment of the winding of the present utility model.

[0029] Figure 12 is the side view of multiple wires that have been helically stranded.

[0030] Figure 13 is the side view of the fourth embodiment of the winding of the present utility model, where the winding has an insulating layer wound around Figure 12 multiple wires that have been helically stranded in

[0031] Figure 14 is Figure 13 the cross - sectional view of the winding in

[0032] Figure 15A - Figure 15B is the schematic diagram of the winding fixture, wire - wrapping fixture and winding process of the present utility model.

[0033] Figure 15C is the schematic diagram of a wire with an insulating layer coated.

[0034] Figure 15D is the schematic diagram after both ends of the wire with an insulating layer coated are cut off.

[0035] Figure 16 is the schematic diagram of the stranding fixture of the present utility model performing the stranding operation.

[0036] Figure 17 is the schematic diagram of the exposed end of the wire that has been stranded by the present utility model.

[0037] Figure 18 is the schematic diagram of the present utility model performing the soldering operation.

[0038] Figure 19A is the schematic diagram of the winding of the present utility model after the soldering operation is completed.

[0039] Figure 19B It is a schematic diagram when the wire winding of the present utility model that has completed the soldering operation is bent.

[0040] Figure 20 It is a three-dimensional external view schematic diagram of the thin transformer of the present utility model.

[0041] Figure 21 It is a three-dimensional exploded schematic diagram of the thin transformer of the present utility model.

[0042] Figure 22 It is a three-dimensional external view schematic diagram of the wire winding frame of the present utility model.

[0043] Figure 23A It is a sectional view of T1 - T1' of an embodiment of the thin transformer of the present utility model.

[0044] Figure 23B It is a sectional view of T2 - T2' of an embodiment of the thin transformer of the present utility model. Figure 24A It is a sectional view of T1 - T1' of another embodiment of the thin transformer of the present utility model

[0045] Figure 24B It is a sectional view of T2 - T2' of another embodiment of the thin transformer of the present utility model.

[0046] Figure 25 It is a schematic diagram of an embodiment of the isolated circuit of the present utility model.

[0047] Figure 26 It is a schematic diagram of another embodiment of the isolated circuit of the present utility model.

[0048] Figure 27 It is a flowchart of the withstand voltage test method of the isolated circuit of the present utility model.

[0049] The reference numerals are as follows:

[0050] 11, 21, 31, 41: Conductors

[0051] 12, 22: Insulation structures

[0052] 121, 321: First insulation layers

[0053] 122: Second insulation layer

[0054] 1221, 2221: First fixing parts

[0055] 1222, 2222: Overlapping parts

[0056] 1223, 2223: Second fixing parts

[0057] 123: First colloid layer

[0058] 124: Second colloid layer

[0059] 125: Third colloid layer

[0060] 100: Wire winding jig

[0061] 101: Fixing part

[0062] 110: Wire wrapping jig

[0063] 111: First component

[0064] 112: Second component

[0065] 200: Twisting jig

[0066] 210: First twisting part

[0067] 220: Second twisting part

[0068] 230: Depression

[0069] 221: First insulating tape

[0070] 222: Second insulating tape

[0071] 300, 300a: Isolated circuit

[0072] 310: Power factor correction circuit

[0073] 311: Rectifying circuit

[0074] 312: Boosting circuit

[0075] 320: Resonant conversion circuit

[0076] 321: Primary circuit

[0077] 322: Resonant circuit

[0078] 323: Secondary circuit

[0079] 310a: Primary circuit

[0080] 311a: Rectifying circuit

[0081] 312a: RCD absorption circuit

[0082] 320a: Secondary circuit

[0083] 411: Core wire

[0084] 412: Coating

[0085] 42: Insulating layer

[0086] 5, 5a: Thin transformer

[0087] 50, 50a: Bobbin

[0088] 51: First plate body

[0089] 52: Second plate body

[0090] 53, 53a: Hollow column

[0091] 60, 60a: Iron core

[0092] 61: First iron core

[0093] 611: First base

[0094] 612: First core column

[0095] 62: Second iron core

[0096] 621: Second base

[0097] 622: Second core column

[0098] 70, 70a: First winding group

[0099] 80, 80a: Second winding group

[0100] 90, 90a: Spacing distance

[0101] A: Conducting wire

[0102] A1: First exposed part

[0103] A2: Coated part

[0104] A3: Second exposed part

[0105] Aa: First exposed end

[0106] Ab: Second exposed end

[0107] Aa1: First soldering part

[0108] Ab1: Second soldering part

[0109] B1: First adhesive layer

[0110] B2: Second adhesive layer

[0111] C1: Bleeder capacitor

[0112] Cf: First output capacitor

[0113] Cfa: Filter capacitor

[0114] Co: Second output capacitor

[0115] Coa: Output capacitor

[0116] Cr: Resonant capacitor

[0117] d1, d2, d3, d4: Diodes

[0118] D1: First wire diameter

[0119] D2: Second wire diameter

[0120] D3: Third wire diameter

[0121] E: Insulating layer

[0122] E1: Edge

[0123] F: Gap

[0124] G: Ground terminal

[0125] I1: First insulating substrate layer

[0126] I2: Second insulating substrate layer

[0127] Ia: Insulating partition layer

[0128] Lf: Energy storage inductor

[0129] Lr: Resonant inductor

[0130] Np: Primary winding

[0131] Ns: Secondary winding

[0132] Q1: First switch

[0133] Q1a: Switch

[0134] Q2: Second switch

[0135] Q3: Third switch

[0136] Q4: Fourth switch

[0137] Q5: Fifth switch

[0138] R: Resistor

[0139] S11, S12, S13, S121, S122, S21, S22, S23, S100, S200: Steps

[0140] T: Transformer

[0141] T1, T1’, T2, T2’: Hatch lines

[0142] V: Carrier

[0143] W11, W21: First width

[0144] W12, W22: Second width

[0145] X, Y, Z: Axes Detailed implementation manners

[0146] Some typical embodiments of the features and advantages of the present utility model will be described in detail in the following description. It should be understood that the present utility model can have various changes in different ways, all of which do not depart from the scope of the present utility model, and the descriptions and drawings therein are essentially for illustrative purposes rather than for limiting the present utility model.

[0147] The present utility model will be further described in detail below with reference to the drawings and specific embodiments: This embodiment is implemented on the premise of the technical solution of the present utility model, and the implementation manners and operation processes are given, but the protection scope of the present utility model is not limited to the following embodiments.

[0148] Please refer to Figure 1 - Figure 2 , Figure 1 , which is a schematic structural diagram of the first winding embodiment of the present utility model, and Figure 2 is Figure 1 's side view. As Figure 1 - Figure 2 shown, the winding of the present utility model includes a wire 11 and an insulating structure 12. The wire 11 can be a basic insulated single-strand wire or a basic insulated multi-strand wire, etc. The insulating structure 12 is wound around and covers the wire 11. The insulating structure 12 includes: a first insulating layer 121 and a second insulating layer 122; the first insulating layer 121 has a first width W11; the second insulating layer 122 has a second width W12. The second insulating layer 122 has an X-axis direction and a Y-axis direction perpendicular to the X-axis direction. The first insulating layer 121 is disposed on the second insulating layer 122 along the direction parallel to the X-axis. The first width W11 is smaller than the second width W12. The part of the wire 11 that is disposed on the second insulating layer 122 along the direction parallel to the X-axis and is not covered by the first insulating layer 121. The first insulating layer 121 and the second insulating layer 122 are wound around and cover the wire 11 along the Y-axis direction. In some embodiments of the present utility model, the first insulating layer 121 and the second insulating layer 122 are wound around and cover the wire 11 such that the number of insulating layers of the winding is at least three to meet the safety regulations requirements. By controlling the first width W11 and / or the second width W2, and the position of the first insulating layer 121 on the second insulating layer 122, the number of insulating layers of the winding can be controlled. The processing method is simple, and compared with the three-layer insulated calico wire, the cost is also lower.

[0149] Further, after the first insulating layer 121 is attached to the second insulating layer 122, the second insulating layer 122 is sequentially divided into a first fixing portion 1221, an overlapping portion 1222, and a second fixing portion 1223 along the Y-axis direction. The wire 11 is disposed on the second fixing portion 1223 along a direction parallel to the X-axis. The width of the first fixing portion 1221 and / or the second fixing portion 1223 may be greater than or equal to the outer circumference of the wire 11, and the width of the overlapping portion 1222 may also be greater than or equal to the outer circumference of the wire 11. In some embodiments of the present invention, the widths of the first fixing portion 1221, the second fixing portion 1223, and the overlapping portion 1222 may be set to be equal to the outer circumference of the wire 11. In this case, the number of insulating layers of the winding is exactly three layers, which is beneficial to further saving materials and reducing costs, and is also easy to realize automated processing. It should be noted that the influence of the thickness of the insulating layer is ignored here.

[0150] Still further, the insulating structure 12 further includes a first colloid layer 123 and a second colloid layer 124. The first colloid layer 123 is disposed on the first fixing portion 1221 and / or the second fixing portion 1223. The wire 11 is disposed on the first colloid layer 123. The first colloid layer 123 is used to more firmly fix the wire 11 on the second insulating layer 122. The second colloid layer 124 is disposed between the overlapping portion 1222 and the first insulating layer 121 for bonding the first insulating layer 121 and the second insulating layer 122. Starting from the second fixing portion 1223 provided with the wire 11, the wire 11 is wound and coated until it is bonded to the first fixing portion 1221. In some embodiments of the present invention, as Figure 2 shown, the thicknesses of the first colloid layer 123 and the second colloid layer 124 can be controlled to be the same.

[0151] It should be noted that in other embodiments, the wire 11 may also be disposed on the first fixing portion 1221 along a direction parallel to the X-axis. Starting from the first fixing portion 1221 provided with the wire 11, the wire 11 is wound and coated until it is bonded to the second fixing portion 1223.

[0152] It should be noted that during the winding process of the winding of the present invention, the wire 11 and the first insulating layer 121 may also be in direct contact, so that the insulating structure 12 can more easily and smoothly wind the wire 11, ensuring that the surface of the processed wire is flat and tight. However, the present invention is not limited thereto.

[0153] Even further, the insulating structure 12 further includes a third colloid layer 125 disposed on the first insulating layer 121. Compared with the above-mentioned direct contact method between the wire 11 and the first insulating layer 121, the advantage of this method is that the wire 11 can be better fixed during the winding process.

[0154] Please refer to Figure 3 - Figure 4 , Figure 3This is a schematic structural diagram of the second embodiment of the winding of the present utility model. Figure 4 It is Figure 3 a side view of. As Figure 3 - Figure 4 shown, the winding of the present utility model includes a wire 21 and an insulating structure 22. The insulating structure 22 is wound around and covers the wire 21. The wire 21 can be a basic insulated single-strand wire or a basic insulated multi-strand wire, etc. The insulating structure 22 includes: a first insulating tape 221 and a second insulating tape 222; the first insulating tape 221 has a first width W21; the second insulating tape 222 has a second width W22. The second insulating tape 222 has an X-axis direction and a Y-axis direction perpendicular to the X-axis direction. The first insulating tape 221 is attached to the second insulating tape 222 along a direction parallel to the X-axis. The first width W21 is smaller than the second width W22. The part of the wire 21 that is arranged along a direction parallel to the X-axis on the second insulating tape 22 and is not covered by the first insulating tape 221. The first insulating tape 221 and the second insulating tape 222 are wound around and cover the wire 21 along the Y-axis direction. In some embodiments of the present utility model, the first insulating tape 221 and the second insulating tape 222 are wound around and cover the wire 21 so that the number of insulating layers of the winding is at least three to meet the safety regulation requirements.

[0155] The first insulating tape 221 includes a first adhesive layer B1 and a first insulating substrate layer I1 arranged back to back. The second insulating tape 222 includes a second adhesive layer B2 and a second insulating substrate layer I2 arranged back to back. The first adhesive layer B1 and the second adhesive layer B2 are attached. That is, after the first insulating tape 221 is attached to the second insulating tape 222, the insulating substrate layer I2 of the second insulating tape 222 is divided into three parts: a first fixed part 2221, an overlapping part 2222, and a second fixed part 2223 along the Y-axis direction. In other words, the first insulating substrate layer I1 and the second insulating substrate layer I2 are respectively the first insulating layer 121 and the second insulating layer 122.

[0156] The wire 21 is arranged on the second fixing part 2223 along the direction parallel to the X-axis. Since there is a second adhesive layer B2 between the second fixing part 2223 and the wire 21, the wire 21 can be more firmly fixed on the second insulating substrate layer I2 before starting winding. When winding and covering the wire 21, when the part of the first insulating tape 221 in contact with the winding is the insulating substrate layer I1, because the contact surface is a smooth plane, the wire 21 can be more easily and smoothly wound, ensuring that the surface of the processed wire is flat and tight. Moreover, since the first fixing part 2221 also has an adhesive layer B2, it can be more conveniently bonded to the second insulating substrate layer I2, and finally the winding is completed to obtain a winding including an insulating layer. In addition, the texture of the insulating tape is relatively soft. When this winding is used for winding the winding group of a transformer or the winding group of other magnetic components, compared with the three-layer insulating kraft paper tape, the gap between windings can be reduced, thereby reducing the volume of the magnetic component and further increasing the power density. It should be noted that in other embodiments, the wire 21 can also be arranged on the first fixing part 2221 along the direction parallel to the X-axis, and start winding and covering the wire 21 from the first fixing part 2221 provided with the wire 21 until it is bonded to the second fixing part 2223.

[0157] In another embodiment of the present invention, the first insulating substrate layer I1 and the second adhesive layer B2 are adhered to divide the insulating substrate layer I2 of the second insulating tape 222 into a first fixing part 2221, an overlapping part 2222, and a second fixing part 2223 in sequence.

[0158] The width of the first fixing part 2221 and / or the second fixing part 2223 can be greater than or equal to the outer circumference of the wire 21, and the width of the overlapping part 2222 can also be greater than or equal to the outer circumference of the wire 21. In some embodiments of the present invention, the widths of the first fixing part 2221, the second fixing part 2223, and the overlapping part 2222 can be set to be equal to the outer circumference of the wire 11, so that the number of insulating layers of the winding is exactly three layers, which is beneficial to further saving materials and reducing costs, and is easy to realize automated processing. It should be noted that the influence of the thickness of the insulating tape is ignored here.

[0159] Please refer to Figure 5 - Figure 6 , Figure 5 For Figure 1 the flowchart of the winding preparation method in Figure 6 and Figure 5 the sub-step flowchart of step S12 in Figure 5 - Figure 6 As shown in

[0160] Step S11: Arrange a first insulating layer with a first width on a second insulating layer with a second width along the X-axis direction of the second insulating layer, where the first width is less than the second width. In an embodiment of the present invention, after the first insulating layer is arranged on the second insulating layer, the second insulating layer is sequentially divided into a first fixing part, an overlapping part, and a second fixing part along the Y-axis direction. The width of the first fixing part and / or the second fixing part can be greater than or equal to the outer circumference of the wire, and the width of the overlapping part can also be greater than or equal to the outer circumference of the wire. In some embodiments of the present invention, the widths of the first fixing part, the second fixing part, and the overlapping part can be set to be equal to the outer circumference of the wire. In this case, the number of insulating layers of the winding is exactly three, which is beneficial to further saving materials and reducing costs, and is also easy to realize automated processing. In another embodiment of the present invention, after the first insulating layer is arranged on the second insulating layer, the second insulating layer is divided into a first fixing part and an overlapping part along the Y-axis direction. The present invention is not limited thereto;

[0161] Step S12: Arrange the wire on the part of the second insulating layer that is not covered by the first insulating layer along the direction parallel to the X-axis; In an embodiment of the present invention, when the second insulating layer is sequentially divided into a first fixing part, an overlapping part, and a second fixing part along the Y-axis direction after the first insulating layer is arranged on the second insulating layer, the wire is arranged on the first fixing part or the second fixing part. The wire can be a basic insulated single-strand wire or a basic insulated multi-strand wire, etc.;

[0162] Step S13: The first insulating layer and the second insulating layer are wound around and covered the wire along the Y-axis direction perpendicular to the X-axis, where the winding and covering of the wire starts from the first fixing part provided with the wire and ends at the second fixing part; or starts from the second fixing part provided with the wire and ends at the first fixing part.

[0163] Furthermore, step S12 further includes:

[0164] Step S121: Arrange a first colloid layer on the first fixing part and / or the second fixing part;

[0165] Step S122: Arrange the wire on the first colloid layer.

[0166] Even further, in step S11, a second colloid layer is also arranged between the overlapping part and the first insulating layer, and / or in step S11, a third colloid layer is also arranged on the first insulating layer.

[0167] In some embodiments of the present invention, the first insulating layer and the second insulating layer are wound around and covered the wire, so that the number of insulating layers of the winding is at least three.

[0168] Please refer to Figure 7 , Figure 7 For Figure 3 is the flowchart of the winding preparation method. AsFigure 7 As shown, the preparation method of the winding of the present utility model includes:

[0169] Step S21: Arrange a first insulating tape with a first width along the X-axis direction of a second insulating tape with a second width on the second insulating tape, where the first width is less than the second width;

[0170] Step S22: Arrange a wire along the part of the second insulating tape that is parallel to the X-axis direction and not covered by the first insulating tape. The wire is a basic insulated single-strand wire or a basic insulated multi-strand wire;

[0171] Step S23: The first insulating tape and the second insulating tape are wound around and covered the wire along the Y-axis direction perpendicular to the X-axis direction.

[0172] Furthermore, in step S21, the first insulating tape includes a first adhesive layer and a first insulating substrate layer arranged back to back, and the second insulating tape includes a second adhesive layer and a second insulating substrate layer arranged back to back. In step S21, the first adhesive layer and the second adhesive layer are adhered, that is, after the first insulating tape is adhered to the second insulating tape, the insulating substrate layer of the second insulating tape is divided into a first fixing part, an overlapping part, and a second fixing part along the Y-axis direction. In other words, the first insulating substrate layer and the second insulating substrate layer are respectively the first insulating layer and the second insulating layer.

[0173] Further, in step S22, the wire is arranged along the X-axis direction on the second fixing part. Since there is a second adhesive layer between the second fixing part and the wire, the wire can be more firmly fixed to the second insulating layer before starting to wind; in step S23, starting from the second fixing part provided with the wire, the first insulating tape and the second insulating tape are wound around and covered the wire until the first fixing part. When winding and covering the wire, since the part of the first insulating tape in contact with the winding is the insulating substrate layer, which is a smooth plane, it will be easier to smoothly wind the wire, ensuring that the surface of the processed wire is flat and tight. And, since there is also an adhesive layer on the first fixing part, it can be more conveniently adhered to the second insulating substrate layer, and finally the winding is completed to obtain a winding including an insulating layer.

[0174] It should be noted that in other embodiments, the wire can also be arranged along the X-axis direction on the first fixing part, and starting from the first fixing part provided with the wire, the wire is wound around and covered until it is adhered to the second fixing part.

[0175] In another embodiment of the present utility model, the first insulating substrate layer and the second adhesive layer are adhered to sequentially divide the insulating substrate layer of the second insulating tape into a first fixing part, an overlapping part, and a second fixing part.

[0176] In some embodiments of the present utility model, the width of the first fixing portion and / or the second fixing portion may be set to be greater than or equal to the wire diameter of the wire, and the width of the overlapping portion is greater than or equal to the wire diameter of the wire. When the widths of the first fixing portion, the second fixing portion, and the overlapping portion are all equal to the wire diameter of the wire, the number of insulating layers of the winding is exactly three, which is beneficial to further saving materials and reducing costs, and is easy to realize automated processing.

[0177] Please refer to Figure 8 , Figure 8 which is a schematic structural diagram of the third embodiment of the winding of the present utility model. As Figure 8 shown, the winding of the present utility model includes: a wire 31 and a first insulating layer 321. The wire 31 is a basically insulated single-strand wire or a basically insulated multi-strand wire. The first insulating layer 321 has an X-axis direction and a Y-axis direction perpendicular to the X-axis direction. The wire 31 is arranged on the first insulating layer 321 along a direction parallel to the X-axis, and the first insulating layer 321 is wound to cover the wire 31 along the Y-axis direction.

[0178] Among them, by setting the width of the first insulating layer 321, after the first insulating layer 321 is wound to cover the wire 31, the number of insulating layers of the winding is at least three. In some embodiments of the present utility model, the first insulating layer 321 may be an insulating base material layer of an insulating tape. The wire 31 is arranged on the first insulating layer 321 along a direction parallel to the X-axis, and the adhesive layer of the insulating tape is between the wire 31 and the first insulating layer 321.

[0179] Please refer to again Figure 1 and Figure 9 , Figure 9 which is Figure 1 the cross-sectional schematic diagram of the winding shown. As Figure 9 shown, the first insulating layer 121 and the second insulating layer 122 are wound to cover the wire 11, so that the number of insulating layers of the winding is at least three.

[0180] Please refer to again Figure 8 and Figure 10 , Figure 10 which is Figure 8 the cross-sectional schematic diagram of the winding shown. As Figure 10 shown, the first insulating layer 321 is wound to cover the wire 31, so that the number of insulating layers of the winding is at least three.

[0181] The present utility model also discloses a winding set of a magnetic component, which includes the winding shown in the foregoing Figure 1 or Figure 3 or Figure 8 , that is, the winding set is wound by the above-mentioned winding.

[0182] Please refer to Figure 11 to Figure 14, in another embodiment, the present utility model further discloses a winding wire, which includes a plurality of conductive wires 41 and an insulating layer 42. The conductive wire 41 can be one of the aforementioned conductive wires 11, 21, and 31, and the insulating layer 42 can be one of the aforementioned insulating structures 12, 22, and insulating layer 321.

[0183] As Figure 11 shown, each conductive wire 41 includes a core wire 411 and a coating 412. The core wire 411 can be made of copper material, and the core wire 411 has a first wire diameter D1 less than or equal to 0.2 mm, so that the core wire 411 can have better flexibility. The coating 412 has a thickness less than or equal to 0.1 mm, preferably between 0.02 mm and 0.03 mm, and the elongation rate of the coating 412 is greater than or equal to 15%, so that the conductive wire 41 formed by covering the core wire 411 with the coating 412 can be easily bent. In addition, the withstand voltage of the coating 412 is greater than or equal to 1 kV, so that the conductive wire 41 has better insulation characteristics.

[0184] The plurality of conductive wires 41 are arranged closely to each other and twisted spirally, and as Figure 12 shown, the plurality of conductive wires 41 are combined with each other in such a way that they are twisted spirally at least 33 times within a length of one meter. In other words, the plurality of conductive wires 41 gathered together will be twisted 360 degrees in the clockwise or counterclockwise direction until at least 33 twists are achieved within a length of one meter. In particular, the number of spiral twists of the plurality of conductive wires 41 can be between 33 and 85 times within a length of one meter. It should be noted that Figure 12 shown is only for illustration and not the actual winding wire situation.

[0185] After the spiral twisting, the plurality of conductive wires 41 will be closely pressed against each other due to the force, and the distance between adjacent conductive wires 41 is less than 0.1 mm. In addition, the plurality of conductive wires 41 can form a circle with a second wire diameter D2 in the cross-sectional direction after the spiral twisting, where D2 ≤ C * √N * D1, C is a constant related to the number of twists, and N is the number of conductive wires 41. In some embodiments, for example, when the plurality of conductive wires 41 are twisted spirally 33 times within a length of one meter, C is 1.115, and the value of C is inversely proportional to the number of spiral twists of the bundled conductive wires.

[0186] After the plurality of conductive wires 41 are twisted spirally, as Figure 13 shown, the insulating layer 42 is then wound around the outside of the conductive wires 41, and the insulating layer 42 is implemented as continuously winding the conductive wires 41 until the number of insulating layers covering the conductive wires 41 reaches at least three layers.

[0187] The wire 41 is tightly wound by the insulating layer 42 such that the distance between each wire 41 located on the circumference of the circle formed after the twisting of multiple wires 41 and the insulating layer 42 is less than 0.1 mm. Furthermore, among the multiple insulating layers 42 covering the wire 41, adjacent insulating layers 42 form a smooth and tight overlap without wrinkles or gaps. The winding formed by winding multiple wires 41 with the insulating layer 42 has a third wire diameter D3, and the third wire diameter D3 is less than the total wire diameter of at least three layers of each wire 41 covered by the insulating layer 42, that is, less than the wire diameter of a known three-layer insulated wire. At the same time, the third wire diameter D3 is also less than the total wire diameter of at least three layers of the multiple wires 41 helically coated with the insulating layer 42. In some embodiments of the present invention, the thickness of the insulating layer 42 is less than or equal to 0.1 mm. Wherein, the total thickness of the multiple insulating layers 42 covering the multiple wires 41 is the thickness of the insulating layer 42 multiplied by the number of layers covering the wire 41.

[0188] Furthermore, as shown in the following table, taking the wire diameter of a single wire 41 being approximately 0.1 mm as an example for calculation, when the second wire diameter D2 after the helical twisting of multiple wires 41 reaches approximately 0.55 - 0.58 mm, the final wire diameter of the winding formed by the continuous winding method of the insulating layer 42 of the present invention, that is, the third wire diameter D3, is less than the wire diameter of a known three-layer insulated wire and the wire diameter of the insulating layer 42 helically coated on the wire 41. In other words, when the number of strands of the wire 41 reaches 33 strands or more, the winding formed according to the method of the present invention can provide a smaller final wire diameter than the prior art.

[0189]

[0190] More specifically, the present invention can effectively increase the thickness of the external insulating layer of the wire while achieving the effect of reducing the final wire diameter of the winding by the method of continuously winding the insulating layer / insulating structure around the wire until the number of insulating layers reaches at least three layers. After winding onto the winding frame, the reduced wire diameter will help reduce the volume of the winding group, increase the distance between different winding groups, and further increase the leakage inductance, so as to reduce the externally added inductance components or even completely replace the externally added inductance components.

[0191] In addition, by forming a single-strand wire through coating the core wire and then forming a winding wire by coating at least three layers of insulating layers on the stranded multi-strand wire, the present utility model further achieves the effect of improving the withstand voltage value of the winding wire. For example, compared with the known three-layer insulated wire with an outer film thickness of 0.09 mm and a withstand voltage value of about 3100 VAC, the insulating layer thickness of the winding wire of the present utility model can reach about 0.15 mm, and the withstand voltage value can reach about 5000 VAC. Moreover, it has been experimentally verified that the winding wire of the present utility model can withstand an arc current of 7.7 mA for 60 seconds, meeting the safety requirements of IEC65960 and IEC60065. Therefore, the winding wire proposed by the present utility model significantly improves the defects of the known three-layer insulated wire.

[0192] During actual implementation, a winding fixture can be further adopted to assist the operation of coating the insulating layer / insulating structure on the wire. As Figure 15A - Figure 15D shown, the winding fixture 100 includes two fixing parts 101 for fixing both ends of the wire A. That is to say, the two fixing parts 101 are arranged along the X-axis direction so that the wire A fixed thereon is also arranged along the X-axis direction. Herein, the wire A refers to the stranded multi-strand wire as described above, such as the multi-strand wire 41 stranded at least 33 times within one meter.

[0193] The insulating layer E has an X-axis direction and a Y-axis direction perpendicular to the X-axis direction. One side E1 parallel to the X direction is fixed on the wire A in a manner parallel to the wire A. Then, the insulating layer E is wound around and coated on the wire A along the Y-axis direction, and the number of coated insulating layers is at least three. It should be noted that the insulating layer E can be the insulating structure 12, 22 or the insulating layer 321, 42 as described above, and is not limited to those shown in the figure.

[0194] Furthermore, a wire-wrapping fixture 110 can be used to assist the process of winding and coating the insulating layer E on the wire A. The wire-wrapping fixture 110 includes a first component 111 and a second component 112 that forms an angle with the first component 111 approximately, so as to form an angular space for accommodating the insulating layer E and the wire A between the two. For example, the angle between the first component 111 and the second component 112 can be about 90 degrees, or the angle can be determined according to the wire diameter of the wire A. During operation, first, after the insulating layer E is fixed on the wire A through the side E1 and preliminarily coats the wire A, the wire A and the insulating layer E are placed together in the angular space formed by the first component 111 and the second component 112. One of the first component 111 and the second component 112 provides the force for fixing and fitting, and the other provides the function of guiding the insulating layer E, and the coating operation of the insulating layer E is completed by rotating the wire-wrapping fixture 110. This helps the insulating layer E to smoothly wind around the wire A and ensures that the surface of the processed wire is flat and tight.

[0195] After the coating of the insulating layer E is completed, for example, after at least three layers of insulating layers have been coated on the outside of the wire A, as Figure 15CAs shown, the wire A disposed on the winding jig 100 is sequentially divided into a first bare portion A1, a coated portion A2, and a second bare portion A3 along the X-axis direction.

[0196] After that, the first bare portion A1 and the second bare portion A3 are respectively cut to form a first bare end Aa and a second bare end Ab, and the wire with the coating completed is separated from the winding jig 100. And after cutting, as Figure 15D shown, the wires of the first bare end Aa and the second bare end Ab are in a dispersed state.

[0197] Next, the first bare end Aa and the second bare end Ab are respectively subjected to a stranding operation and a soldering operation to complete the preparation before winding onto the winding frame. Here, since the stranding operations of the first bare end Aa and the second bare end Ab are the same, only the first bare end Aa will be described.

[0198] The stranding operation is to form a spiral stranding as Figure 12 - 14 shown, for example, a spiral stranding with at least thirty-three spiral twists within a length of one meter. In one embodiment, the stranding operation is completed by a stranding jig. As Figure 16 shown, the stranding jig 200 includes a first stranding portion 210 and a second stranding portion 220. The to-be-stranded first bare end Aa is disposed between the first stranding portion 210 and the second stranding portion 220, and the stranding operation is completed by clamping both sides of the first bare end Aa by the first stranding portion 210 and the second stranding portion 220 and rotating them simultaneously. In one embodiment, the first stranding portion 210 and the second stranding portion 220 respectively have a recess 230 along the longitudinal direction, for example, an arc-shaped recess, to form a space for accommodating the to-be-stranded bare end when they face each other. After the stranding operation is completed, the end of the first bare end Aa forms a conical shape (as Figure 17 shown) and the wires of the first bare end Aa are closely adjacent to each other. For example, the interval between adjacent wires is less than 0.1 mm. In addition, by performing the stranding operation in this way, the wire diameter tolerance after stranding falls within + / -0.18 mm.

[0199] Next, the first bare end Aa and the second bare end Ab with the ends stranded into a conical shape further perform a soldering operation. In one embodiment, the soldering operation can be carried out in the following manner. As Figure 18 shown, a plurality of windings that have completed the stranding operation are arranged at intervals and clamped in the carrier V, and the conical ends to be soldered are exposed on the opposite sides of the carrier V. Then, by moving the carrier V, a plurality of windings are simultaneously soldered through the furnace. The soldering conditions can vary according to requirements and are not limited.

[0200] After the soldering operation is completed, the first exposed end Aa and the second exposed end Ab respectively form a first soldering part Aa1 and a second soldering part Ab1, which serve as the pins after being wound around the winding frame. As Figure 19A and Figure 19B shown, in the present utility model, when performing the soldering operation on the first exposed end Aa and the second exposed end Ab, a part close to the covering part A2 is left unsoldered respectively. That is to say, there is a gap F between both ends of the covering part A2 and the first soldering part Aa1 and the second soldering part Ab1. The function of this gap F is to ensure that when the completed winding is wound around the winding frame, enough space can be provided for the soldering part to be bent into a pin, avoiding the pins from being unable to be bent to the required angle due to the covering of soldering and / or the insulating layer. At the same time, the gap F can also prevent the insulating tape from cracking when being bent after covering the insulating tape. Here, the bending angle α is defined as the included angle between the soldering parts Aa1, Ab1 of the winding and the covering part A2. Therefore, this gap F is roughly inversely proportional to the bending angle α required for the pin. That is to say, when the bending angle α required for the pin is smaller, the gap F needs to be larger; on the other hand, this gap F is also proportional to the wire diameter of the wire A. That is to say, when the wire diameter of the wire is larger, the gap F needs to be larger. In an embodiment, when the gap F is between 0.5 mm and 3 mm, the bending angle α is greater than or equal to 90 degrees.

[0201] Next, the winding with both ends having completed stranding and soldering performs the winding operation. Here, two windings are taken as an example for illustration, but not limited thereto. One end (the soldered end) of the winding is first set on the winding frame, and different windings can be marked for distinction. Then, according to the type of the transformer, the corresponding winding operation is performed. After the winding is completed, the other end (the soldered end) of the winding is set on the winding frame again, and then the winding is fixed with adhesive tape. It should be noted that according to different requirements, both ends of the winding can be fixed on the same side or opposite sides of the winding frame, without limitation.

[0202] In summary, the process of the present utility model from forming the winding from the wire to winding it around the winding frame is that multiple strands of wires form a stranded wire in a way of helically stranding at least thirty-three times within one meter. The outside of the stranded wire is covered with at least three layers of insulating layer. Both ends of the covering part are respectively cut off to form exposed ends. The exposed ends perform the stranding operation and the soldering operation to complete the preparation before winding. After that, the prepared winding is wound around the winding frame to form a winding group, and the soldered end is used as the pin. It should be noted that the winding of the present utility model can be applied to magnetic component structures such as transformers and inductors.

[0203] In some embodiments of the present utility model, on the premise of adopting the winding of the present utility model and cooperating with further designing the structure of the transformer, the requirement of effectively reducing the overall height of the transformer while maintaining the inductance of the switching power supply can be effectively achieved.

[0204] Please refer to Figure 20 、 Figure 21 and Figure 22 , which respectively show the three-dimensional external view schematic diagram of the thin transformer of the present utility model, the three-dimensional exploded schematic diagram of the thin transformer, and the three-dimensional external view schematic diagram of the bobbin. The thin transformer 5 of the present utility model includes a bobbin 50, a pair of iron cores 60, a first winding group 70, and a second winding group 80. The bobbin 50 has a first plate body 51 and a hollow column 53 protruding from the first plate body 51. Specifically, the bobbin 50 has a second plate body 52 relative to the first plate body 51. The hollow column 53 is between the first plate body 51 and the second plate body 52.

[0205] The pair of iron cores 60 are arranged on opposite sides of the bobbin 50 and include a first iron core 61 and a second iron core 62. The first iron core 61 has a first base 611 and a first core column 612 connected to the first base 611. The second iron core 62 has a second base 621 and a second core column 622 connected to the second base 621. In addition, the first base 611 is attached to the first plate body 51. The second base 621 is attached to the second plate body 52. The first core column 612 and the second core column 622 pass through the hollow column 53.

[0206] Furthermore, the first winding group 70 (or the primary side winding) surrounds the hollow column 53 and is arranged on the first plate body 51 and is located between the pair of iron cores 60. The second winding group 80 (or the secondary side winding) surrounds the first winding group 70 and is arranged on the first plate body 51. There is a spacing distance 90 between the second winding group 80 and the first winding group 70. In actual implementation, the spacing distance 90 is not less than 0.2 mm and not greater than 13.5 mm, but it is not limited thereto. In actual implementation, the first winding group 70 and / or the second winding group 80 adopt windings with the aforementioned structure, which provide characteristics such as small wire diameter and easy tight winding. Therefore, in this architecture, the thickness of the thin transformer 5 can be less than 20 mm. More specifically, the high-voltage winding in the first winding group 70 or the second winding group 80 can adopt a winding with the aforementioned structure.

[0207] Please also refer to Figure 22 、 Figure 23A and Figure 23B , in which Figure 23A and Figure 23B respectively show the cross-sectional views of T1-T1' and T2-T2' of an embodiment of the thin transformer of the present utility model. It can be seen from the figure that the first winding group 70 and the second winding group 80 surround the hollow column 53 in the radial direction of the hollow column 13, and the first winding group 70 and the second winding group 80 are concentrically arranged on the first plate body 51.

[0208] Please refer to again Figure 24A and Figure 24B, which respectively show the cross-sectional views of T1-T1' and T2-T2' of another embodiment of the thin transformer of the present utility model. In this embodiment, the thin transformer 5a includes a bobbin 50a, a pair of iron cores 60a, a first winding group 70a, and a second winding group 80a. The bobbin 50a has a hollow column 53a. The pair of iron cores 60 are arranged on opposite sides of the bobbin 50a. The first winding group 70a and the second winding group 80a are concentrically arranged around the hollow column 53a in the radial direction of the hollow column 53a and are located between the pair of iron cores 60a. In addition, there is a spacing distance 90a between the second winding group 80a and the first winding group 70a.

[0209] The difference in this embodiment is that the thin transformer 1a further includes an insulating layer Ia. The insulating layer Ia is made of an insulating material and is arranged in the spacing distance 90a. In addition, the thickness of the insulating layer Ia is not less than 0.2 mm and not greater than 13.5 mm. Accordingly, both sides of the insulating layer Ia are respectively abutted against the first winding group 70a and the second winding group 80a to ensure the spacing distance 90a between the first winding group 70a and the second winding group 80a, thereby increasing the leakage inductance of the thin transformer 5a.

[0210] In actual implementation, the setting of the spacing distance or the insulating layer can increase the leakage inductance by more than 15%, so as to replace the resonant inductor of the traditional transformer with an LLC circuit, that is, the function of the LLC circuit can be realized without an external resonant inductor.

[0211] On the other hand, the winding with at least three layers of insulating layers in the present utility model can be applied to an isolated circuit, such as the primary winding (such as the aforementioned first winding groups 70, 70a), the secondary winding (such as the aforementioned second winding groups 80, 80a) of the transformer constituting the isolated circuit, and / or the winding of the inductor, etc., so as to make the isolated circuit have the characteristic of high voltage resistance.

[0212] In one embodiment, the switching power supply can be an isolated circuit, such as Figure 25 As shown, the isolated circuit 300 can include a power factor correction (PFC) circuit 310 and a resonant conversion circuit 320. Among them, the resonant conversion circuit 320 can be an LLC resonant circuit. The power factor correction circuit 310 includes a rectifier circuit 311 and a boost circuit 312 connected in series in sequence. The rectifier circuit 311 is electrically connected to the input end of the isolated circuit 300 for receiving an AC input voltage and converting it into a DC voltage. The boost circuit 312 is electrically connected to the rectifier circuit 311 for increasing the DC voltage.

[0213] The resonant conversion circuit 320 includes a primary circuit 321, a resonant circuit 322, and a secondary circuit 323 connected in series in sequence. The primary circuit 321 is electrically connected to the power factor correction circuit 310. The resonant circuit 322 includes a resonant inductor Lr, a resonant capacitor Cr, and a transformer T. The transformer T includes a primary winding Np and a secondary winding Ns. The primary winding Np and the secondary winding Ns are electromagnetically coupled, and the resonant inductor Lr, the resonant capacitor Cr, and the primary winding Np are connected in series. The secondary winding Ns induces a secondary voltage according to the voltage on the primary winding Np. The secondary circuit 323 is electrically connected between the secondary winding Ns and the output end of the isolation circuit 300, and is used to receive the secondary voltage generated by the secondary winding Ns and convert it into an output voltage to be output at the output end of the isolation circuit 300. Among them, the resonant inductor Lr can be an externally added physical inductor element, or can be composed of the leakage inductance formed by the spacing distance or the insulating layer between the primary winding and the secondary winding. When the resonant inductor Lr can be an externally added physical inductor element, the resonant inductor can include the aforementioned winding, that is, a winding having a wire (such as one of the aforementioned wires 11, 21, 31, 41, and A) and an insulating layer covering the wire (such as one of the aforementioned insulating structures 12, 22, and insulating layers 321, E).

[0214] In some embodiments of the present invention, the primary winding Np and / or the secondary winding Ns in the above isolation circuit include the aforementioned winding, that is, a winding having a wire (such as one of the aforementioned wires 11, 21, 31, 41, and A) and an insulating layer covering the wire (such as one of the aforementioned insulating structures 12, 22, and insulating layers 321, E). The present invention achieves the effect of improving the withstand voltage value of the winding by the way of covering at least three layers of insulating layers outside the wire. For example, compared with the known three-layer insulated wire with an outer film thickness of 0.09 mm and a withstand voltage value of about 3100 VAC, the insulating layer thickness of the winding in the present invention is about 0.15 mm, and the withstand voltage value can reach about 5000 VAC. Therefore, when the isolation circuit uses the winding covering at least three layers of insulating layers in the present invention to form an inductive component, when the input end and the output end of the isolation circuit are short-circuited for a high-voltage test, the withstand voltage value between the primary circuit and the secondary circuit can reach about 4000 VAC to 5000 VAC.

[0215] Specifically, the rectifier circuit 311 is electrically connected to the input end of the isolation type circuit 300 and includes a full-bridge rectification architecture composed of four diodes d2. In other embodiments of the present invention, the rectifier circuit can also be composed of four controllable switching tubes such as MOS tubes to form a full-bridge rectification architecture, or can be a half-bridge rectification architecture. The boost circuit 312 includes a storage inductor Lf, a first switch Q1, a first output capacitor Cf, and a diode d1. The first end of the storage inductor Lf is electrically connected to the rectifier circuit 311. The first power terminal of the first switch Q1 is electrically connected to the second end of the storage inductor Lf, and the second power terminal of the first switch Q1 is electrically connected to the ground terminal G. The anode terminal of the diode d1 is electrically connected to the first power terminal of the first switch Q1 and the second end of the storage inductor Lf. The first end of the first output capacitor Cf is electrically connected to the cathode terminal of the diode d1, and the second end of the first output capacitor Cf is electrically connected to the ground terminal G. The primary circuit 321 is an inverter circuit including a second switch Q2 and a third switch Q3. The second switch Q2 and the third switch Q3 are serially electrically connected between the cathode terminal of the diode d1 and the ground terminal G, and the resonance inductor Lr and the resonance capacitor Cr are serially electrically connected between the connection point between the second switch Q2 and the third switch Q3 and the ground terminal G in series with the primary winding Np. In other embodiments of the present invention, the inverter circuit can also be a full-bridge inverter architecture. The secondary circuit 323 includes a fourth switch Q4, a fifth switch Q5, and a second output capacitor Co. The first power terminal of the fourth switch Q4 is electrically connected to the first end of the secondary winding Ns, and the second power terminal of the fourth switch Q4 is electrically connected to the output negative terminal of the output end of the isolation type circuit 300. The first power terminal of the fifth switch Q5 is electrically connected to the second end of the secondary winding Ns, and the second power terminal of the fifth switch Q5 is electrically connected to the output negative terminal of the output end of the isolation type circuit 300. The secondary winding Ns also has a center tap terminal, which is electrically connected to the output positive terminal of the output end of the isolation type circuit 300. The second output capacitor Co is electrically connected between the output positive terminal and the output negative terminal.

[0216] It should be noted that when the leakage inductance formed by the interval distance or the insulating layer between the primary winding and the secondary winding constitutes the resonance inductor Lr, the primary winding Np and / or the secondary winding Ns in the LLC circuit includes the aforementioned winding, that is, a winding having a wire (such as one of the aforementioned wires 11, 21, 31, 41, and A) and an insulating layer covering the wire (such as one of the aforementioned insulating structures 12, 22, and insulating layers 321, E), and the leakage inductance, or the magnitude of the resonance inductor Lr, can be increased according to

[0217] where Q is the quality factor, Lr is the resonance inductor, Cr is the resonance capacitor, and R is the load. Thus, it can be seen that the increase of Lr can improve the quality factor of the circuit.

[0218] In another embodiment, as Figure 26As shown, the isolated circuit 300a can be a flyback circuit, and includes a primary circuit 310a, a transformer T, and a secondary circuit 320a, where the structure and function of the transformer T are similar to Figure 25 the structure and function of the transformer T shown. Here, only the same symbols are used to label it, and no further description will be given. The primary circuit 310a includes a rectifier circuit 311a, a filter capacitor Cfa, a switch Q1a, and an RCD snubber circuit 312a composed of a resistor R, a discharge capacitor C1, and a diode d3. The rectifier circuit 311a is electrically connected to the input end of the isolated circuit 300a and includes a full-bridge rectifier structure composed of four diodes d2. In other embodiments of the present invention, the rectifier circuit can also be a full-bridge rectifier structure composed of four controllable switch tubes such as MOS tubes, or a half-bridge rectifier structure. The first end of the filter capacitor Cfa is electrically connected to the first end of the rectifier circuit 313a and the primary winding Np. The second end of the filter capacitor Cfa is electrically connected to the ground terminal G. The switch Q1a is electrically connected between the second end of the primary winding Np and the ground terminal G. The resistor R and the discharge capacitor C1 are connected in parallel and electrically connected between the first end of the filter capacitor Cfa and the cathode terminal of the diode d3. The anode terminal of the diode d3 is electrically connected between the switch Q1a and the second end of the primary winding Np.

[0219] In some embodiments, the secondary circuit 320a includes a diode d4 and an output capacitor Coa. The anode terminal of the diode d4 is electrically connected to the first end of the secondary winding Ns. The cathode terminal of the diode d4 is electrically connected to the positive output terminal of the output end of the isolated circuit 300a. The output capacitor Coa is electrically connected between the positive output terminal and the negative output terminal. In addition, the second end of the secondary winding Ns is electrically connected to the negative output terminal of the output end of the isolated circuit 300a.

[0220] Please refer to Figure 27 , which is a withstand voltage test method applied to the isolated circuit of the present invention, and includes the following steps.

[0221] Step S100: Provide an isolated circuit (such as the aforementioned isolated circuits 300, 300a), where the isolated circuit includes a power factor correction circuit and a resonant conversion circuit connected in series in sequence. The resonant conversion circuit includes, connected in series in sequence: a primary circuit electrically connected to the power factor correction circuit; a resonant circuit including a resonant inductor, a resonant capacitor, and a transformer, where the transformer includes a primary winding and a secondary winding, and the resonant inductor, the resonant capacitor, and the primary winding are connected in series; and a secondary circuit electrically connected to the secondary winding. At least one of the primary winding, the secondary winding, and the resonant inductor has a winding including a wire and an insulating layer / insulating structure covering the wire. After one side of the insulating layer / insulating structure parallel to the X-axis direction is fixed to a wire arranged along the X-axis direction, the wire is then wound and covered along the Y-axis direction perpendicular to the X-axis direction until the number of insulating layers of the covered wire is at least 3 layers.

[0222] Step S200: Short-circuit the input end and the output end of the isolated circuit to perform a high-voltage test and obtain the withstand voltage value between the input end and the output end of the isolated circuit.

[0223] As described above, when the isolated circuit includes a primary winding and / or a secondary winding that adopts the winding with at least three layers of insulation layers covered by the present invention, the withstand voltage value between its input end and output end can be increased to 4000VAC to 5000VAC.

[0224] In summary, the winding of the present invention has the advantages of being easy to realize automated processing, easy to wind smoothly, and having a flat and tight surface of the wire after processing, which helps to improve the power density of the magnetic component, and can meet the requirement of enhanced insulation while having a low material production cost. In addition, on the premise of increasing the thickness of the external insulation layer of the wire by covering at least three layers of insulation layers, the winding preparation method of the present invention achieves the goal of reducing the final wire diameter of the winding. This not only helps to reduce the volume of the winding group and increase the space between winding groups, but also achieves the effects of reducing the overall height of the transformer and increasing the leakage inductance. Furthermore, the winding prepared by the present invention with at least three layers of insulation layers covered further provides advantages such as having a withstand voltage value and meeting safety regulations.

[0225] It should be noted that the above is only a preferred embodiment proposed to illustrate the present invention. The present invention is not limited to the described embodiment, and the scope of the present invention is determined by the appended claims. And the present invention can be variously modified by those skilled in the art, but all do not depart from what the appended claims intend to protect.

Claims

1. An isolated circuit, characterized in that: The invention comprises a power factor correction circuit and a resonant conversion circuit connected in series in sequence, wherein the resonant conversion circuit comprises: a primary circuit electrically connected to the power factor correction circuit; A resonant circuit comprising a resonant inductor, a resonant capacitor and a transformer, wherein the transformer comprises a primary winding and a secondary winding, and the resonant inductor, the resonant capacitor and the primary winding are connected in series; and a secondary circuit electrically connected to the secondary winding; The primary winding and / or the secondary winding includes a winding, and the winding includes a conductor and an insulating layer covering the conductor. The insulating layer is fixed on the conductor arranged along the X-axis direction with one side parallel to the X-axis direction, and then wound and covered the conductor along the Y-axis direction perpendicular to the X-axis direction until the number of insulating layers covering the conductor is at least 3 layers. The withstand voltage between the input and output ends of the isolated circuit is 4000VAC to 5000VAC.

2. The isolated circuit according to claim 1, characterized in that: The power factor correction circuit comprises: a rectifier circuit; and A boost circuit, the boost circuit comprising: an energy storage inductor, a first end of which is electrically connected to the rectifier circuit; a first switch, wherein a first power terminal of the first switch is electrically connected to a second terminal of the energy storage inductor, and a second power terminal of the first switch is electrically connected to a ground terminal; a diode, an anode terminal of the diode being electrically connected to the first power terminal of the first switch; and A first output capacitor has a first terminal electrically connected to a cathode terminal of the diode, and a second terminal electrically connected to the ground terminal.

3. The isolated circuit according to claim 2, characterized in that: The primary circuit includes an inverter circuit electrically connected to the boost circuit, and the inverter circuit includes: a second switch; and a third switch, electrically connected in series with the second switch between the cathode terminal of the diode and the ground terminal; The secondary circuit includes: a fourth switch, wherein a first power terminal of the fourth switch is electrically connected to a first terminal of the secondary winding, and a second power terminal of the fourth switch is electrically connected to an output negative terminal of the isolation circuit; a fifth switch, a first power terminal of the fifth switch being electrically connected to a second terminal of the secondary winding, and a second power terminal of the fifth switch being electrically connected to the negative output terminal of the isolation circuit; and a second output capacitor electrically connected between an output positive terminal and the output negative terminal of the isolation circuit; and The secondary winding also has a central tap end electrically connected to the output positive end of the isolation circuit.

4. The isolated circuit according to claim 1, characterized in that: The winding includes a plurality of conductors which are twisted spirally at least 33 times within a length of one meter.

5. The isolated circuit according to claim 4, characterized in that: Each of the multiple wires includes a core wire and a coating, the core wire has a first wire diameter, the multiple wires that have been spirally twisted have a second wire diameter, the winding wire has a third wire diameter, and the third wire diameter is smaller than the total wire diameter of the insulation layer covering at least 3 layers of each of the multiple wires, and the third wire diameter is smaller than the total wire diameter of the insulation layer spirally covering at least three layers of the multiple wires.

6. The isolated circuit according to claim 5, characterized in that: The number of strands of the plurality of conducting wires is greater than or equal to 33, and the second wire diameter is at least 0.55 mm.

7. The isolated circuit as claimed in claim 1, wherein the insulating layer comprises an insulating tape.

8. The isolated circuit according to claim 1, characterized in that: There is a spacing distance between the primary winding and the secondary winding.

9. The isolated circuit according to claim 8, characterized in that: An insulating layer is arranged between the spacing distances.

10. The isolated circuit according to claim 9, characterized in that: The resonant inductance is formed by the leakage inductance formed by the separation distance or the insulating barrier.

11. The isolated circuit according to claim 1, characterized in that: When the resonant inductor is an external inductor element, the resonant inductor includes the winding.

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