High-reliability pulse transformer and network transformer

Abstract

The utility model relates to the technical field of magnetic devices, and discloses a high-reliability pulse transformer and network transformer, and the high-reliability pulse transformer comprises a magnetic core which comprises a middle column, and a first flange and a second flange which are respectively connected to the two ends of the middle column; the first electrode, the second electrode, the third electrode and the fourth electrode are arranged on the first flange at intervals; the fifth electrode and the sixth electrode are arranged on the second flange at intervals; the primary winding and the secondary winding are wound on the middle column and are respectively provided with a primary center tap and a secondary center tap, leads at two ends of the primary winding are respectively connected with the first electrode and the second electrode, leads at two ends of the secondary winding are respectively connected with the third electrode and the fourth electrode, and leads at two ends of the secondary winding are respectively connected with the third electrode and the fourth electrode. And the primary center tap and the secondary center tap are respectively connected with the fifth electrode and the sixth electrode. The reliability of the device is improved.

Description

Technical Field

[0001] The present application relates to the technical field of magnetic devices, and in particular to a high-reliability pulse transformer and a network transformer. Background Art

[0002] The network transformer module is an indispensable part of the network card circuit. Its basic components mainly include a pulse transformer, a common-mode filter, an intermediate tap capacitor, and an autotransformer. Network transformers are used in various Ethernet devices for data transmission (transmitting the signal transmitted from the data line end to the device IC end through coupling), high-voltage isolation (isolating the device IC end from the outside to prevent surge or lightning damage to the device IC), voltage matching (the voltage levels transmitted from the data line end are different, and the network transformer is used to isolate and adjust them), and signal noise suppression (filtering out noise common-mode signals to improve signal quality).

[0003] The network transformer in the related technology generally adopts a separate structure with fully automated wire winding. The I-shaped magnetic core is wound and welded, and then assembled with the cover to form a closed magnetic circuit. However, the pulse transformer contained in this type of network transformer is very likely to cause the lead to burn back during hot pressing welding of the lead joint, resulting in a decrease in the product's voltage resistance margin or even voltage resistance failure. This situation needs to be changed. Utility Model Content

[0004] In view of this, the present application provides a high-reliability pulse transformer and network transformer to solve the above-mentioned technical problems.

[0005] To achieve the above objectives, according to the first aspect, the technical solution adopted is:

[0006] A high-reliability pulse transformer, comprising:

[0007] The magnetic core comprises a center column and a first flange and a second flange respectively connected to two ends of the center column;

[0008] A first electrode, a second electrode, a third electrode and a fourth electrode are arranged on the first flange at intervals;

[0009] a fifth electrode and a sixth electrode, arranged at intervals on the second flange;

[0010] The primary winding and the secondary winding are wound on the center column and have a primary center tap and a secondary center tap, respectively, wherein the two end leads of the primary winding are respectively connected to the first electrode and the second electrode, the two end leads of the secondary winding are respectively connected to the third electrode and the fourth electrode, and the primary center tap and the secondary center tap are respectively connected to the fifth electrode and the sixth electrode.

[0011] The present application is further configured as follows: the first electrode, the second electrode, the third electrode and the fourth electrode are respectively connected to the end surface of the first flange, or are respectively connected to the end surface and the side surface of the first flange in an L shape.

[0012] The present application is further configured as follows: the fifth electrode and the sixth electrode are respectively connected to the end surface of the second flange, or are respectively connected to the end surface and side surface of the second flange in an L-shape.

[0013] The present application is further configured as follows: the end surface of the first flange and the end surface of the second flange are external surfaces of the pulse transformer, and the external surfaces face the PCB board or external equipment.

[0014] The present application is further configured as follows: the first electrode and the second electrode arranged at intervals are located on one side of the end surface of the first flange, and the third electrode and the fourth electrode arranged at intervals are located on the other side of the end surface of the first flange.

[0015] The present application is further configured as follows: the fifth electrode is located on one side of the end surface of the second flange, and the sixth electrode is located on the other side of the end surface of the second flange.

[0016] The present application is further configured as follows: the primary winding includes a first wire and a third wire, and the secondary winding includes a second wire and a fourth wire;

[0017] The first wire and the second wire are staggered on the center column, one end of the first wire is connected to the first electrode, and the other end thereof is connected to the fifth electrode, and one end of the second wire is connected to the third electrode, and the other end thereof is connected to the sixth electrode;

[0018] The third wire and the fourth wire are arranged alternately on the center column, one end of the third wire is connected to the second electrode, and the other end thereof is connected to the fifth electrode, and one end of the fourth wire is connected to the fourth electrode, and the other end thereof is connected to the sixth electrode.

[0019] The present application is further configured as follows: the first wire and the second wire constitute a first wire layer, the third wire and the fourth wire constitute a second wire layer, the first wire layer and the second wire layer are stacked on the center column, wherein the winding directions of the first wire layer and the second wire layer are opposite.

[0020] According to the second aspect, the technical solution adopted is:

[0021] A network transformer comprises the high-reliability pulse transformer as described in any one of the above embodiments.

[0022] In summary, compared with the prior art, the present application discloses a high-reliability pulse transformer and network transformer, the pulse transformer comprising: a magnetic core, comprising a middle column and a first flange and a second flange respectively connected to the two ends of the middle column, the first electrode, the second electrode, the third electrode and the fourth electrode are arranged at intervals on the first flange, the fifth electrode and the sixth electrode are arranged at intervals on the second flange, the primary winding and the secondary winding are wound on the middle column and have a primary center tap and a secondary center tap respectively, the leads at both ends of the primary winding are connected to the first electrode and the second electrode respectively, the leads at both ends of the secondary winding are connected to the third electrode and the fourth electrode respectively, the primary center tap and the secondary center tap are connected to the fifth electrode and the sixth electrode respectively, thus designing, the creepage distance between the leads and the center taps is ensured, which can reduce the electrical interference between the winding leads on the one hand, and reduce the damage to the insulation layer of the wire sheath due to the heat from welding on the other hand, thereby significantly improving the withstand voltage capability of the device. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following is a brief introduction to the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present application. For those skilled in the art, other drawings can be obtained based on these drawings without creative work.

[0024] Figure 1 This is a schematic diagram of the first structure of the high-reliability pulse transformer of the present application;

[0025] Figure 2 This is a second structural diagram of the high-reliability pulse transformer of the present application;

[0026] Figure 3 It is a partial cross-sectional structural diagram of the winding and the center column of the present application. DETAILED DESCRIPTION

[0027] Exemplary embodiments will be described in detail herein, with examples illustrated in the accompanying drawings. When the following description refers to the drawings, identical numbers in different figures represent identical or similar elements unless otherwise indicated. The embodiments described in the following exemplary embodiments are not intended to represent all embodiments consistent with the present application. Rather, they are merely examples of apparatus and methods consistent with certain aspects of the present application, as detailed in the appended claims.

[0028] It should be noted that, in this document, the terms "include", "comprises" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, an element defined by the sentence "comprising a ..." does not exclude the presence of other identical elements in the process, method, article or device comprising the element. In addition, components, features, and elements with the same name in different embodiments of the present application may have the same meaning or different meanings, and their specific meanings need to be determined based on their explanation in the specific embodiment or further combined with the context of the specific embodiment.

[0029] It should be understood that the specific embodiments described herein are only used to explain the present application and are not intended to limit the present application.

[0030] In the subsequent description, the use of suffixes such as "module", "component" or "unit" to represent elements is only for the purpose of facilitating the description of the present application and has no specific meaning. Therefore, "module", "component" or "unit" can be used interchangeably.

[0031] In the description of this application, it should be noted that the terms "upper," "lower," "left," "right," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate the description of this application and simplify the description. They do not indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0032] The technical solutions shown in this application will be described in detail below through specific embodiments. It should be noted that the description order of the following embodiments does not limit the priority order of the embodiments.

[0033] In the related art, traditional magnetic ring network transformers are composed of a wire package and a plastic shell. The connection between the wire package and the plastic shell requires a lot of manual winding, which is time-consuming and labor-intensive, with extremely low efficiency and difficult to ensure quality. In order to reduce processing difficulty and improve product quality, with the update of equipment and technological breakthroughs, industry technicians have developed a separate structure that can be fully automated. By winding and welding the I-shaped magnetic core and then assembling it with a cover plate, a closed magnetic circuit is formed to replace the traditional magnetic ring network transformer. However, in the existing separate network transformer, the primary lead terminal electrode and the secondary center tap electrode of the pulse transformer are on the same platform. The lead burnback caused by hot pressing can easily cause the device's voltage resistance margin to decrease or even voltage resistance failure. One solution is to add a right-angle lead fixture, that is, use a right-angle lead fixture at the end of the winding of the wire package to temporarily bend and fix the lead, and then perform lead terminal or center tap welding to increase the lead length. However, this process increases the winding failure rate and operation time, increases the production cycle, and reduces production capacity. Therefore, the present application discloses a high-reliability pulse transformer and network transformer.

[0034] refer to Figures 1 to 3 The high-reliability pulse transformer of the present application includes a magnetic core 1, a primary winding 6, a secondary winding 7, a first electrode 31, a second electrode 32, a third electrode 33, a fourth electrode 34, a fifth electrode 41 and a sixth electrode 42.

[0035] In which, the magnetic core 1 includes a middle column 2 and a first flange 3 and a second flange 4 respectively connected to the two ends of the middle column 2, the first electrode 31, the second electrode 32, the third electrode 33, and the fourth electrode 34 are arranged at intervals on the first flange 3, and the fifth electrode 41 and the sixth electrode 42 are arranged at intervals on the second flange 4, wherein the primary winding 6 and the secondary winding 7 are wound on the middle column 2 and have a primary center tap 8 and a secondary center tap 9 respectively. Specifically, the two end leads of the primary winding 6 are respectively connected to the first electrode 31 and the second electrode 32, the two end leads of the secondary winding 7 are respectively connected to the third electrode 33 and the fourth electrode 34, the primary center tap 8 and the secondary center tap 9 are respectively connected to the fifth electrode 41 and the sixth electrode 42.

[0036] In the pulse transformer of this embodiment, the winding end leads are connected to the electrodes of the first flange 3 at intervals, and the primary and secondary center taps are connected to the electrodes of the second flange 4 at intervals. This increases the creepage distance between the winding end leads and the center taps. On the one hand, it can reduce the electrical interference between the leads, and on the other hand, it can reduce the damage to the insulation layer of the wire sheath caused by heat from welding, thereby significantly improving the voltage resistance of the device.

[0037] In this embodiment, the first flange 3 and the second flange 4 are arranged at both ends of the center column 2, thereby forming an I-shaped or H-shaped magnetic core, so as to ensure the stability and symmetry of the structure of the magnetic core 1, and the primary winding 6 and the secondary winding 7 are evenly distributed around the center column 2, thereby ensuring the magnetic field strength and improving the electromagnetic performance and reliability of the device.

[0038] In one embodiment, the pulse transformer further includes a magnetic cover plate 10 , which is disposed on one side of the magnetic core 1 and respectively connected to the first flange 3 and the second flange 4 to form a closed magnetic circuit.

[0039] Preferably, the first flange 3 and the second flange 4 are respectively provided with an adhesive layer 101 at one end facing away from the first electrode 31, the second electrode 32, the third electrode 33, the fourth electrode 34, the fifth electrode 41 and the sixth electrode 42, and the adhesive layer 101 is connected to the magnetic cover plate 10, thereby the magnetic cover plate 10 is bonded and fixed to the magnetic core 1, thereby improving the structural strength of the device.

[0040] In a specific implementation process, the first electrode 31 , the second electrode 32 , the third electrode 33 and the fourth electrode 34 can be respectively connected to the end surface of the first flange 3 , or respectively connected to the end surface and the side surface of the first flange 3 in an L-shape.

[0041] In addition, the fifth electrode 41 and the sixth electrode 42 can be respectively connected to the end face of the second flange 4, or respectively connected to the end face and side face of the second flange 4 in an L-shape, thereby extending the arrangement length of the two end leads of the primary winding 6 and the two end leads of the secondary winding 7 and the primary center tap 8 and the secondary center tap 9 on the magnetic core 1, reducing the damage to the insulation layer of the wire sheath caused by heat from welding, significantly improving the voltage resistance of the device, and improving the reliability of the device.

[0042] The end surface of the first flange 3 and the end surface of the second flange 4 are external connection surfaces of the pulse transformer, which face the PCB board or external equipment and are used for electrical connection between the pulse transformer and the outside world.

[0043] It can be understood that the end of the first flange 3 and the second flange 4 where the adhesive layer 101 is provided can be the inner connecting surface of the first flange 3 and the second flange 4 .

[0044] Preferably, the first electrode 31 and the second electrode 32 arranged at intervals can be located on one side of the end surface of the first flange 3, and the third electrode 33 and the fourth electrode 34 can be located on the other side of the end surface of the first flange 3, thereby ensuring the distance between the two end leads of the primary winding 6 and the two end leads of the secondary winding 7, so as to reduce electrical interference between the leads and reduce damage to the insulation layer of the wire wrapping conductor due to heat caused by welding.

[0045] In addition, the fifth electrode 41 can be located on one side of the end face of the second flange 4, and the sixth electrode 42 can be located on the other side of the end face of the second flange 4, thereby ensuring the distance between the primary center tap 8 and the secondary center tap 9, and reducing the damage to the insulation layer of the wire-wrapped conductor caused by the heat brought by welding.

[0046] Among them, the first electrode 31, the second electrode 32, the third electrode 33 and the fourth electrode 34 have a first preset height relative to the first flange 3, and the fifth electrode 41 and the sixth electrode 42 have a second preset height relative to the second flange 4. The first preset height and the second preset height are adjustable.

[0047] In the specific implementation process, the two end leads of the primary winding 6 can be respectively the first lead end 61 and the second lead end 62, that is, the first lead end 61 is connected to the first electrode 31, and the second lead end 62 is connected to the second electrode 32, and the two end leads of the secondary winding 7 can be respectively the third lead end 71 and the fourth lead end 72, the third lead end 71 is connected to the third electrode 33, and the fourth lead end 72 is connected to the fourth electrode 34.

[0048] Among them, the spacing distance between the first electrode 31 and the second electrode 32 arranged on the first flange 3 is adjustable, the spacing distance between the third electrode 33 and the fourth electrode 34 arranged on the first flange 3 is adjustable, and the spacing distance between the fifth electrode 41 and the sixth electrode 42 arranged on the second flange 4 is adjustable.

[0049] In addition, the primary center tap 8 includes a first tap end 81 and a second tap end 82 interconnected to the fifth electrode 41, and the secondary center tap 9 includes a third tap end 91 and a fourth tap end 92 interconnected to the sixth electrode 42, that is, the primary center tap 8 and the secondary center tap 9 are connected to the fifth electrode 41 and the sixth electrode 42, respectively.

[0050] In a specific implementation process, the primary winding 6 includes a first wire 51a and a third wire 52a, and the secondary winding 7 includes a second wire 51b and a fourth wire 52b, wherein the first wire 51a and the second wire 51b can constitute a first wire layer 51, and the third wire 52a and the fourth wire 52b can constitute a second wire layer 52.

[0051] Specifically, the first wire 51a and the second wire 51b are arranged in a staggered manner on the middle column 2, one end of the first wire 51a is connected to the first electrode 31, and the other end thereof is connected to the fifth electrode 41, one end of the second wire 51b is connected to the third electrode 33, and the other end thereof is connected to the sixth electrode 42, and the third wire 52a and the fourth wire 52b are arranged in a staggered manner on the middle column 2, one end of the third wire 52a is connected to the second electrode 32, and the other end thereof is connected to the fifth electrode 41, one end of the fourth wire 52b is connected to the fourth electrode 34, and the other end thereof is connected to the sixth electrode 42. By staggering the first wire 51a and the second wire 51b and the staggered third wire 52a and the fourth wire 52b, the spacing between the wire layers can be ensured to be uniform, the phenomenon of unbalanced electromagnetic coupling can be avoided, and the reliability of the device can be improved.

[0052] That is, the two ends of the first wire 51a are the first lead end 61 and the first tap end 81 respectively, the two ends of the second wire 51b are the third lead end 71 and the third tap end 91 respectively, the two ends of the third wire 52a are the second lead end 62 and the second tap end 82 respectively, and the two ends of the fourth wire 52b are the fourth lead end 72 and the fourth tap end 92 respectively. Then the first lead end 61 and the first tap end 81 are collinear, the second lead end 62 and the second tap end 82 are collinear, the third lead end 71 and the third tap end 91 are collinear, and the fourth lead end 72 and the fourth tap end 92 are collinear, thereby closing the primary winding 6 coil and the secondary winding 7 coil of the winding package 5, optimizing the electromagnetic field distribution and transmission performance of the device.

[0053] In this embodiment, the first wire layer 51 and the second wire layer 52 are stacked on the center column 2, and the winding directions of the first wire layer 51 and the second wire layer 52 are opposite to each other, so as to offset part of the stray magnetic field generated by the wire current, thereby reducing electromagnetic interference (EMI) and improving device reliability.

[0054] Through the arrangement and layout design of the electrodes in this embodiment, there is no need to add a right-angle lead-out fixture in the related art, and straight-pull welding can be performed, thereby shortening the production cycle of the device winding process, improving production efficiency, reducing the occurrence of defects, and thus reducing manufacturing costs.

[0055] In one embodiment, based on the contents of the aforementioned embodiments, the first electrode 31, the second electrode 32, the third electrode 33 and the fourth electrode 34 can be arranged at intervals along the first direction on the first flange 3, wherein the first direction has an angle with the axial direction of the center column 2, and the fifth electrode 41 and the sixth electrode 42 can be arranged at intervals along the first direction on the second flange 4, so that the two ends of the primary winding 6 are respectively connected to the first electrode 31 and the second electrode 32, and the two ends of the secondary winding 7 are respectively connected to the third electrode 33 and the fourth electrode 34, and the primary center tap 8 and the secondary center tap 9 are respectively connected to the fifth electrode 41 and the sixth electrode 42.

[0056] It should be noted that the first direction of the present application and the axial direction of the center column 2 have an angle, that is, the first direction and the axial direction of the center column 2 are not parallel to each other in the same plane. This embodiment can also be provided with a second direction, the second direction can be perpendicular to the first direction and the axial direction of the center column 2, and the angle between the first direction and the axial direction of the center column 2 can be 90° or other preset angles. When the first direction, the second direction and the axial direction of the center column 2 are perpendicular to each other, reference can be made to Figure 1 The constructed XYZ spatial coordinates, the X-axis direction can be regarded as the first direction, the Z-axis direction can be regarded as the second direction, the Y-axis direction can be regarded as the axial direction of the middle column 2, the axial direction of the middle column 2 can also be regarded as the left and right extension direction of the pulse transformer, the first direction can also be regarded as the front and back extension direction of the pulse transformer, and the second direction can also be regarded as the up and down extension direction of the pulse transformer. Of course, this embodiment is not limited to this. XYZ can also be any other directions perpendicular to each other in space in actual needs, which will not be repeated here.

[0057] Among them, the first wire 51a and the second wire 51b can be arranged in an staggered manner on the center column 2 along the axial direction of the center column 2, and the third wire 52a and the fourth wire 52b can be arranged in an staggered manner on the center column 2 along the axial direction of the center column 2, that is, the first wire 51a and the third wire 52a constitute the primary winding 6 of the pulse transformer, and the second wire 51b and the fourth wire 52b constitute the secondary winding 7 of the pulse transformer.

[0058] The first wire layer 51 and the second wire layer 52 are stacked in the second direction, and the winding directions of the first wire layer 51 and the second wire layer 52 are opposite to each other, so as to offset part of the stray magnetic field generated by the wire current, thereby reducing electromagnetic interference (EMI) and improving device reliability.

[0059] An embodiment of the present application also provides a network transformer, which may include a pulse transformer as described in the above embodiments. Compared with related technologies, the primary and secondary winding leads of the network transformer in this embodiment are arranged on the flange of the same magnetic core, and the primary and secondary center taps are arranged on the other flange of the same magnetic core. Combined with the electrode structure design on the flange, the creepage distance between the leads and the center taps is increased. On the one hand, the electrical interference between the leads can be reduced, and on the other hand, the damage to the insulation layer of the wire sheath due to heat from welding can be reduced, thereby significantly improving the voltage resistance of the device.

[0060] For other working principles and processes of the network transformer in this embodiment, please refer to the description of the pulse transformer in the aforementioned embodiment of the present invention, which will not be repeated here.

[0061] The above is a detailed introduction to the high-reliability pulse transformer and network transformer provided by this application. This article uses specific examples to illustrate the principles and implementation methods of this application. It should be noted that in this application, the descriptions of each embodiment have their own emphasis. For parts that are not detailed or recorded in a particular embodiment, please refer to the relevant descriptions of other embodiments.

[0062] The above are only preferred embodiments of the present application and do not limit the patent scope of the present application. The various technical features of the technical solution of the present application can be arbitrarily combined. In order to make the description concise, all possible combinations of the various technical features in the above embodiments are not described. Any equivalent structure or equivalent process transformation made using the contents of the description and drawings of this application, or directly or indirectly applied in other related technical fields, as long as there is no contradiction in the combination of these technical features, are also included in the patent protection scope of the present application.

Claims

1. A high reliability pulse transformer, characterized in that: include: The magnetic core comprises a center column and a first flange and a second flange respectively connected to two ends of the center column; A first electrode, a second electrode, a third electrode and a fourth electrode are arranged on the first flange at intervals; a fifth electrode and a sixth electrode, arranged at intervals on the second flange; The primary winding and the secondary winding are wound on the center column and have a primary center tap and a secondary center tap, respectively, wherein the two end leads of the primary winding are respectively connected to the first electrode and the second electrode, the two end leads of the secondary winding are respectively connected to the third electrode and the fourth electrode, and the primary center tap and the secondary center tap are respectively connected to the fifth electrode and the sixth electrode.

2. The high-reliability pulse transformer according to claim 1, characterized in that: The first electrode, the second electrode, the third electrode and the fourth electrode are respectively connected to the end surface of the first flange, or are respectively connected to the end surface and the side surface of the first flange in an L shape.

3. The high-reliability pulse transformer according to claim 2, characterized in that: The fifth electrode and the sixth electrode are respectively connected to the end surface of the second flange, or are respectively connected to the end surface and side surface of the second flange in an L-shape.

4. The high-reliability pulse transformer according to claim 3, characterized in that: The end surface of the first flange and the end surface of the second flange are external connection surfaces of the pulse transformer, and the external connection surfaces face the PCB board or external equipment.

5. The high-reliability pulse transformer according to claim 2, characterized in that: The first electrodes and the second electrodes arranged at intervals are located on one side of the end surface of the first flange, and the third electrodes and the fourth electrodes arranged at intervals are located on the other side of the end surface of the first flange.

6. The high-reliability pulse transformer according to claim 3, characterized in that: The fifth electrode is located on one side of the end surface of the second flange, and the sixth electrode is located on the other side of the end surface of the second flange.

7. The high-reliability pulse transformer according to claim 1, wherein: The primary winding includes a first wire and a third wire, and the secondary winding includes a second wire and a fourth wire; The first wire and the second wire are staggered on the center column, one end of the first wire is connected to the first electrode, and the other end thereof is connected to the fifth electrode, and one end of the second wire is connected to the third electrode, and the other end thereof is connected to the sixth electrode; The third wire and the fourth wire are arranged alternately on the center column, one end of the third wire is connected to the second electrode, and the other end thereof is connected to the fifth electrode, and one end of the fourth wire is connected to the fourth electrode, and the other end thereof is connected to the sixth electrode.

8. The high-reliability pulse transformer according to claim 7, characterized in that: The first wire and the second wire constitute a first wire layer, the third wire and the fourth wire constitute a second wire layer, the first wire layer and the second wire layer are stacked on the center column, wherein the winding directions of the first wire layer and the second wire layer are opposite.

9. A network transformer, characterized in that: The network transformer comprises a high-reliability pulse transformer as described in any one of claims 1-8.

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