High-frequency pulse modulation transformer

Abstract

The utility model relates to a high-frequency pulse modulation transformer which comprises two symmetrically-arranged fixing frames and two parallel secondary winding pipes connected to the fixing frames, each secondary winding pipe is wound with a plurality of Litz coils, and all the Litz coils are located between the two fixing frames. The distances between every two adjacent litz wire bags are equal, the litz wire bag located at the topmost end of the secondary winding pipe is an upper secondary coil, and the other litz wire bags are electrically connected and combined into a lower secondary coil; two groups of primary coils with different inductances are wound on the fixing frame, and a high-temperature insulating tape is arranged between the two groups of primary coils. By arranging two groups of primary coils with different inductances, the working under different output powers can be realized by switching the primary coils with different inductances, for example, the primary coil with a larger inductance value is used during low-power output, so that the energy transmission efficiency is improved; and during high-power output, the primary coil with a smaller inductance value is switched to, so that the power requirement is met.

Description

Technical Field

[0001] The utility model relates to the technical field of transformers, in particular to a high-frequency pulse modulation transformer. Background Art

[0002] A transformer uses the principle of electromagnetic induction to change AC voltage. Its main components are a primary coil, a secondary coil, and a toroidal core. Its primary functions include voltage conversion, current conversion, impedance conversion, isolation, and voltage stabilization. Based on their application, they can be categorized into power transformers and special transformers (e.g., furnace transformers, rectifier transformers, power frequency test transformers, voltage regulators, mining transformers, audio transformers, medium frequency transformers, high frequency transformers, impulse transformers, instrument transformers, electronic transformers, reactors, and mutual inductors). High-frequency transformers operate at frequencies exceeding the medium frequency (10kHz). They are primarily used in high-frequency switching power supplies, but are also used in high-frequency inverters and high-frequency welding machines. Depending on the operating frequency, they can be divided into several grades: 10kHz-50kHz, 50kHz-100kHz, 100kHz-500kHz, 500kHz-1MHz, and above 10MHz. However, the primary coil of existing transformers cannot be modified based on actual conditions after production, meaning their inductance remains fixed. Utility Model Content

[0003] The purpose of the utility model is to provide a high-frequency pulse modulation transformer to solve the problems raised in the above background technology.

[0004] To achieve the above-mentioned objectives, the technical solution adopted by the present invention is: a high-frequency pulse modulation transformer, including two symmetrically arranged fixing frames and two parallel secondary winding tubes connected to the fixing frames, each secondary winding tube is wound with multiple Litz wire packages, and all Litz wire packages are located between the two fixing frames; the spacing between two adjacent Litz wire packages is equal, the Litz wire package located at the top of the secondary winding tube is the upper secondary coil, and the other Litz wire packages are electrically connected and combined to form the next secondary coil; two groups of primary coils with different inductances are wound on the fixing frames, and a high-temperature insulating tape is provided between the two groups of primary coils.

[0005] Compared with the existing technology, by setting two groups of primary coils with different inductances, it is possible to operate at different output powers by switching primary coils with different inductance values. For example, a primary coil with a larger inductance value is used at low power output to improve energy transmission efficiency; and a primary coil with a smaller inductance value is switched to meet power requirements at high power output.

[0006] According to the preferred technical solution of the present invention, a wire outlet hole is provided at the lower end of the secondary winding tube, and the end wire of the next secondary coil passes through the wire outlet hole and extends to the secondary winding tube, and the start wire of the next secondary coil passes through the top of the secondary winding tube. With the end wire outlet hole as a reference, the starting position of the start wire is located on the opposite side of the wire outlet hole and is arranged at an angle.

[0007] According to the preferred technical solution of the present invention, the fixing frame comprises two mounting plates of the same structure and a primary winding frame arranged between the two mounting plates; the two groups of primary coils are wound flatly and closely on the primary winding frame.

[0008] According to the preferred technical solution of the present invention, a mounting hole is provided on the mounting plate and a connecting column is provided on one side of the mounting plate, a double-pass copper nut is installed in the connecting column; and a secondary winding tube is installed in the mounting hole.

[0009] According to the preferred technical solution of the utility model, a fixing column is installed in the secondary winding tube, the fixing column is located at the top of the secondary winding tube, and a double-pass copper nut is fixedly installed in the fixing column by interference fit; a magnetic core assembly is provided in the secondary winding tube, and the magnetic core assembly is threadedly connected to the double-pass copper nut in the fixing column.

[0010] The preferred technical solution of the utility model is that the magnetic core assembly includes a threaded rod connected to a double-pass copper female thread in a fixed column, one end of the threaded rod extends into the secondary winding tube, and the other end is located outside the secondary winding tube; a magnetic core center column is threadedly connected to the threaded rod, the magnetic core center column is located in the secondary winding tube, and a nickel-zinc ferrite magnetic ring is sleeved on the fixed column.

[0011] According to the preferred technical solution of the present invention, a driving groove is provided on the end of the central column of the magnetic core.

[0012] According to the preferred technical solution of the present invention, the length of the nickel-zinc ferrite magnetic ring is greater than the length of the core center column; and the gap between the nickel-zinc ferrite magnetic ring and the core center column is filled with epoxy resin.

[0013] In the preferred technical solution of the present utility model, a locking nut is threadedly connected to the threaded rod, and the locking nut is located outside the secondary winding tube and abuts against the fixing column.

[0014] According to the preferred technical solution of the present invention, the Litz wire package is formed by winding a continuous conductor on a secondary winding tube; the circumference of the secondary winding tube and the width of the Litz wire package form a rectangular winding area; the winding area is divided into four passing areas of equal area, and the conductor continuously passes through the diagonals of two adjacent passing areas for winding.

[0015] In addition to the technical problems solved by the present invention, the technical features that constitute the technical solutions, and the advantages brought about by the technical features of these technical solutions described above, other technical problems that can be solved by the present invention, other technical features included in the technical solutions, and the advantages brought about by these technical features will be further described in detail in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a three-dimensional diagram of the present utility model.

[0017] Figure 2 It is a cross-sectional view of the utility model.

[0018] Figure 3 It is a top view of the fixing bracket of the utility model.

[0019] Figure 4 This is a distribution diagram of the sub-secondary coil and the upper secondary coil being fixed on the winding tube of the utility model.

[0020] Figure 5 This is a schematic diagram of the winding of the Litz wire package of the utility model

[0021] Explanation of the accompanying numbers: 01, fixing frame; 02, secondary winding tube; 03, mounting plate; 04, primary winding frame; 05, mounting hole; 06, connecting column; 07, double-pass copper flower nut; 08, fixing column; 09, threaded rod; 10, core center column; 11, nickel-zinc ferrite magnetic ring; 12, driving slot; 13, Litz wire package; 14, primary coil; 15, lower secondary coil; 16, upper secondary coil; 17, locking nut; 18, wire outlet hole. DETAILED DESCRIPTION

[0022] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0023] See also Figure 1-4 As shown, the high-frequency pulse modulation transformer of the present invention comprises two symmetrically arranged fixing frames 01 and two parallel secondary winding tubes 02 connected to the fixing frames 01.

[0024] See also Figure 3As shown, the fixing frame 01 includes two mounting plates 03 of identical structure and a primary winding frame 04 disposed between the two mounting plates 03. The two mounting plates 03 and the primary winding frame 04 are manufactured using QSY ultra-black resin through 3D printing. Alternatively, they can be integrally manufactured using other materials through injection molding or other processes. The mounting plates 03 are provided with mounting holes 05 and a connecting post 06 disposed on one side of the mounting plates 03. A double-pass copper nut 07 is mounted within the connecting post 06. The double-pass copper nut 07 is pressed tightly into the connecting post 06. The installation of the double-pass copper nut 07 on the mounting plates 03 is to secure it to the external housing or other components. The secondary winding tube 02 is mounted within the mounting hole 05 on the mounting plates 03.

[0025] Mounted within the secondary winding tube 02 is a fixed post 08, located at the top of the secondary winding tube 02. Made of polyoxymethylene rod, it secures a double-pass copper nut 07 within the post through an interference fit. A magnetic core assembly is threaded onto the double-pass copper nut 07 within the post 08.

[0026] See also Figure 2 As shown, the magnetic core assembly includes a threaded rod 09 threadedly connected to a double-pass copper nut 07 within a fixed column 08. One end of the threaded rod 09 extends into the secondary winding tube 02, while the other end is located outside the secondary winding tube 02. A magnetic core center post 10 is threadedly connected to the threaded rod 09 and located within the secondary winding tube 02. A drive slot 12 is provided at the end of the magnetic core center post 10. Drive slot 12 can be cross-shaped or straight. When drive slot 12 is straight, a flat-blade screwdriver is placed in drive slot 12 and the operator rotates the flat-blade screwdriver to tighten the magnetic core center post 10 onto the threaded rod 09. If drive slot 12 is cross-shaped, the operator uses a Phillips screwdriver to tighten the magnetic core center post 10 onto the threaded rod 09 when connecting the magnetic core center post 10 and threaded rod 09. A nickel-zinc ferrite ring 11 is sleeved onto the fixed column 08. The length of the nickel-zinc ferrite ring 11 is greater than that of the magnetic core center post. The gap between the nickel-zinc ferrite magnetic ring 11 and the core center column 10 is filled with epoxy resin, and the core center column 10 and the nickel-zinc ferrite magnetic ring 11 are fixedly connected by the epoxy resin.

[0027] In order to improve the stability between the magnetic core assembly and the fixing post 08 , a locking nut 17 is threadedly connected to the threaded rod 09 , and the locking nut 17 is located outside the secondary winding tube 02 and abuts against the fixing post 08 .

[0028] See also Figure 4As shown, each secondary winding tube 02 is wound with multiple Litz wire packages 13, all of which are located between two fixed frames 01. The spacing between adjacent Litz wire packages 13 is equal. The Litz wire package 13 at the top of the secondary winding tube 02 serves as the upper secondary coil 16, and the remaining Litz wire packages 13 are electrically connected and combined to form the lower secondary coil 15. In this application, seven Litz wire packages 13 are evenly distributed on the secondary winding tube 02. The Litz wire package 13 at the top of the secondary winding tube 02 forms the upper secondary coil 16, and the remaining six Litz wire packages 13 constitute the lower secondary coil 15.

[0029] Placing the Litz wire packages 13 at uniform spacing on the secondary winding tube 02 creates a more uniform magnetic field distribution during operation. This helps improve the transformer's coupling efficiency, enabling more efficient transmission of the magnetic field generated by the primary coil 14 and minimizing energy loss. This uniform magnetic field distribution also reduces the risk of localized overheating, improving the transformer's reliability and stability.

[0030] Designing only two adjacent Litz wire packages 13 with the same spacing can reduce leakage inductance. Reducing leakage inductance can reduce electromagnetic interference and improve circuit performance. Furthermore, uniform spacing helps improve the heat dissipation of the transformer. Air can flow more smoothly between the secondary coils, removing heat and lowering the transformer's operating temperature. Good heat dissipation can extend the transformer's service life and improve its operating efficiency.

[0031] The Litz wire package 13 is wound counterclockwise around the secondary winding tube 02 using a honeycomb winding method. Using a multi-section honeycomb coil allows the distance between sections to be changed to adjust the inductance. A single section coil can only reduce the number of turns to reduce the inductance.

[0032] The Litz wire package 13 is formed by winding a continuous wire around a secondary winding tube 02. The perimeter (H) of the secondary winding tube 02 and the width (D) of the Litz wire package form a rectangular winding area. The winding area is divided into four equal-sized passing areas, and the wire is wound continuously through the diagonal lines of two adjacent passing areas (such as Figure 5 (as shown) effectively reduces the partial capacitance and solves the skin effect of current under high frequency conditions.

[0033] The four-fold honeycomb winding method allows for a more organized arrangement of coils within a limited space. Compared to traditional winding methods, it allows for more turns within the same transformer volume, thereby increasing the inductance of the secondary coil and improving transformer performance. This is particularly important for electronic devices with strict space requirements. It also reduces the effects of capacitance: During transformer operation, distributed capacitance exists between the coils. Honeycomb winding effectively reduces this distributed capacitance. Excessive distributed capacitance can lead to signal distortion, increased energy loss, and other problems. By reducing distributed capacitance, the transformer's high-frequency characteristics are improved, making it more adaptable to the transmission and conversion of high-frequency signals.

[0034] The lower end of the secondary winding tube 02 is provided with a wire outlet hole 18. The end wire of the secondary coil 15 extends through the outlet hole 18 to the secondary winding tube 02. The starting wire of the secondary coil 15 passes through the top of the secondary winding tube 02. With the end wire outlet hole 18 as a reference, the starting wire position is located on the opposite side of the outlet hole 18 and is set at an angle. In this application, the starting wire position is located at a 140° position on the opposite side of the outlet hole 18.

[0035] Setting a specific angle can optimize the magnetic field coupling between the secondary coil and the primary coil 14 to a certain extent. Choosing a suitable angle can make the magnetic field distribution more conducive to energy transmission and improve the transformer's conversion efficiency. It can also reduce magnetic field leakage, allowing more magnetic flux to be effectively transferred between the primary and secondary coils, thereby reducing energy loss.

[0036] Two sets of primary coils 14 with different inductances are wound around the primary winding frame 04. These two sets of primary coils 14 are tightly wound flatly within the primary winding frame 04, with a high-temperature insulation tape placed between them. By providing two sets of primary coils 14 with different inductances, the device can operate at different output powers by switching between the primary coils 14 with different inductances. For example, a primary coil 14 with a higher inductance can be used at low power output to improve energy transmission efficiency; at high power output, the device can switch to a primary coil 14 with a lower inductance to meet power requirements.

[0037] If the embodiments of the present invention involve directional indications (such as up, down, left, right, front, back, etc.), such directional indications are only used to explain the relative position relationship, movement status, etc. between the various components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0038] The above embodiments are merely descriptions of preferred embodiments of the present invention and do not limit the scope of the present invention. Without departing from the design spirit of the present invention, various modifications and improvements made to the technical solutions of the present invention by ordinary engineering technicians in this field should fall within the scope of protection determined by the claims of the present invention.

Claims

1. A high-frequency pulse modulation transformer, characterized in that: The invention comprises two symmetrically arranged fixing frames and two parallel secondary winding tubes connected to the fixing frames. Each secondary winding tube is wound with multiple Litz wire packages, and all the Litz wire packages are located between the two fixing frames. The spacing between two adjacent Litz wire packages is equal. The Litz wire package located at the top of the secondary winding tube is the upper secondary coil, and the other Litz wire packages are electrically connected and combined to form the next secondary coil. Two groups of primary coils with different inductances are wound on the fixing frames, and a high-temperature insulating tape is provided between the two groups of primary coils.

2. The high-frequency pulse modulation transformer according to claim 1, characterized in that: A wire outlet hole is provided at the lower end of the secondary winding tube. The end wire of the next secondary coil passes through the wire outlet hole and extends to the secondary winding tube. The start wire of the next secondary coil passes through the top of the secondary winding tube. With the end wire outlet hole as a reference, the starting position of the start wire is located on the opposite side of the wire outlet hole and is set at an angle.

3. The high-frequency pulse modulation transformer according to claim 1, wherein: The fixing frame comprises two mounting plates with the same structure and a primary winding frame arranged between the two mounting plates; two groups of primary coils are wound flatly and closely on the primary winding frame.

4. The high-frequency pulse modulation transformer according to claim 3, characterized in that: The mounting plate is provided with a mounting hole and a connecting column arranged on one side of the mounting plate, a double-pass copper nut is installed in the connecting column; the secondary winding tube is installed in the mounting hole.

5. The high-frequency pulse modulation transformer according to claim 1, wherein: A fixing column is installed in the secondary winding tube, and the fixing column is located at the top of the secondary winding tube. A double-pass copper nut is fixedly installed in the fixing column by interference fit; a magnetic core assembly is provided in the secondary winding tube, and the magnetic core assembly is threadedly connected to the double-pass copper nut in the fixing column.

6. The high-frequency pulse modulation transformer according to claim 5, characterized in that: The magnetic core assembly includes a threaded rod connected to a double-pass copper female thread in a fixed column, one end of the threaded rod extends into the secondary winding tube, and the other end is located outside the secondary winding tube; a magnetic core center column is threadedly connected to the threaded rod, and the magnetic core center column is located in the secondary winding tube. A nickel-zinc ferrite magnetic ring is sleeved on the fixed column.

7. The high-frequency pulse modulation transformer according to claim 6, characterized in that: A driving groove is provided on the end of the central column of the magnetic core.

8. The high-frequency pulse modulation transformer according to claim 7, characterized in that: The length of the nickel-zinc ferrite magnetic ring is greater than the length of the core center column; and the gap between the nickel-zinc ferrite magnetic ring and the core center column is filled with epoxy resin.

9. The high-frequency pulse modulation transformer according to claim 8, characterized in that: A locking nut is threadedly connected to the threaded rod. The locking nut is located outside the secondary winding tube and abuts against the fixing column.

10. The high-frequency pulse modulation transformer according to claim 1, characterized in that: The Litz wire package is formed by winding a continuous conductor on a secondary winding tube; the circumference of the secondary winding tube and the width of the Litz wire package form a rectangular winding area; the winding area is divided into four passing areas of equal area, and the conductor is continuously wound through the diagonals of two adjacent passing areas.

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