Transformer

Abstract

The utility model discloses a transformer which comprises a framework, the framework comprises a front side plate, a rear side plate and a winding reel, a first PIN position, a second PIN position, a third PIN position and a fourth PIN position at the bottom of the front side plate are all provided with inserting needles, and a fifth PIN position is shorn and does not exceed the bottommost end face of the front side plate; the magnetic core is arranged in the magnetic core fixing hole in a penetrating manner; the magnetic core is provided with an air gap close to the front side plate; the winding is arranged in the winding groove, and the winding comprises a first winding S1, a second winding N1, a third winding N2, a fourth winding N3, a fifth winding S2 and a sixth winding N4 which are sequentially wound outwards in the radial direction of the periphery of the winding reel; thus, the problems that a new product depends on redesign of a mold, so that the cost is high, and the delivery cycle is long are effectively solved, meanwhile, through improvement of the framework and combination of the arrangement of the magnetic core and the winding, the customer requirements can be quickly responded, and the cost is controllable.

Description

Technical Field

[0001] This utility model relates to the field of transformers, and in particular to a transformer. Background Technology

[0002] Transformers typically consist of a frame, core, and windings. Different transformers require different frames, some with varying pin counts and others with different pin arrangements. The frame design process involves creating a 3D model based on customer-provided drawings or samples, combined with the design experience of R&D personnel. This model is then gradually modified until a final design is finalized. This process presents numerous challenges for both the supplier and the customer. Even slight dimensional discrepancies render existing molds unusable. Simpler designs require the creation of a new mold for a specific part, while more complex designs necessitate the creation of an entire mold, significantly increasing transformer manufacturing costs. In the industry, it is common for transformer manufacturers to be unable to accept orders due to the lack of suitable molds.

[0003] We need to produce a high-frequency transformer that requires four long pins and one short pin on one side, and no pins on the other side. Redesigning the mold to produce the frame would be costly and have a long delivery cycle. For orders with small quantities and short lead times, redesigning the mold is not a suitable option.

[0004] Therefore, a new technical solution needs to be developed to address the above problems. Utility Model Content

[0005] In view of this, the present invention addresses the deficiencies of the existing technology and its main purpose is to provide a transformer that effectively solves the problem of high cost and long delivery cycle caused by the reliance on redesigning molds for new products. At the same time, through improvements to the frame and the arrangement of the magnetic core and windings, the transformer product is easy to manufacture and meets the electrical characteristics requirements such as inductance, leakage inductance, withstand voltage and high voltage. For orders with small quantities and short delivery times, it can quickly respond to customer needs and keep costs under control.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A transformer, comprising:

[0008] The frame includes a front side plate, a rear side plate, and a winding cylinder integrally connected between the front side plate and the rear side plate. The winding cylinder has a magnetic core fixing hole inside, which penetrates the front side plate and the rear side plate in the front-rear direction. The outer periphery of the winding cylinder has a winding groove located between the front side plate and the rear side plate. The bottom of the front side plate has a first PIN 1, a second PIN 2, a third PIN 3, a fourth PIN 4, and a fifth PIN 5 spaced apart on the left and right. The first PIN 1, the second PIN 2, the third PIN 3, and the fourth PIN 4 all retain pins. The fifth PIN 5 is shortened and does not extend beyond the bottom end face of the front side plate.

[0009] A magnetic core is inserted into a fixing hole; the magnetic core is provided with an air gap, which is located near the front side where the first PIN 1, the second PIN 2, the third PIN 3, the fourth PIN 4, and the fifth PIN 5 are located;

[0010] The winding is disposed in the winding groove. The winding includes a first winding S1, a second winding N1, a third winding N2, a fourth winding N3, a fifth winding S2, and a sixth winding N4, which are wound radially outward from the outer periphery of the winding drum. The starting and ending wires of the fourth winding N3 emerge from the top of the rear side plate. The starting and ending wires of the first winding S1, the second winding N1, the third winding N2, the fifth winding S2, and the sixth winding N4 are arranged at the bottom of the front side plate to connect to the corresponding first PIN 1, second PIN 2, third PIN 3, fourth PIN 4, and fifth PIN 5.

[0011] As a preferred embodiment, the bottom left and right spacing of the rear panel is provided with a sixth PIN 6, a seventh PIN 7, an eighth PIN 8, a ninth PIN 9, and a tenth PIN 10, and the pins of the sixth PIN 6, the seventh PIN 7, the eighth PIN 8, the ninth PIN 9, and the tenth PIN 10 are removed.

[0012] As a preferred embodiment, the magnetic core includes an E-shaped magnetic block and an I-shaped magnetic block. The central post of the E-shaped magnetic block extends from the rear end into the fixing hole of the magnetic core. The I-shaped magnetic block is assembled with the front end of the E-shaped magnetic block, and the air gap is formed between the I-shaped magnetic block and the E-shaped magnetic block.

[0013] As a preferred embodiment, the air gap is provided with a gasket made of non-magnetic material.

[0014] As a preferred embodiment, the front end face of the central column of the E-shaped magnetic block is glued and fixed to the center of the rear end face of the I-shaped magnetic block.

[0015] As a preferred embodiment, the starting pin of the first winding S1 is the second pin 2, and the ending pin is NC;

[0016] The starting pin of the second winding N1 is the third pin 3, and the ending pin is the fifth pin 5;

[0017] The starting pin of the third winding N2 is the fourth pin 4, and the ending pin is the first pin 1;

[0018] The starting pin of the fourth winding N3 is S, and the ending pin is F;

[0019] The starting PIN of the fifth winding S2 is 1, and the ending PIN is NC.

[0020] The starting pin of the sixth winding N4 is the fifth pin 5, and the ending pin is the second pin 2.

[0021] As a preferred embodiment, the starting and ending wires of the fourth winding N3 are both fitted with a first Teflon sleeve.

[0022] As a preferred embodiment, a second Teflon sleeve is also fitted on the tail wire of the sixth winding N4.

[0023] As a preferred embodiment, the first winding S1 is wound along the outer peripheral wall of the winding drum, and the outer peripheral surface of the first winding S1 is fully covered with the first insulating tape.

[0024] The second winding N1 is wound along the outer peripheral surface of the first insulating tape, and the outer peripheral surface of the second winding N1 is completely covered by the second insulating tape;

[0025] The third winding N2 is wound along the outer peripheral surface of the second insulating tape, and the outer peripheral surface of the third winding N2 is completely covered by the third insulating tape;

[0026] Before winding the fourth winding N3, apply a reverse-folded tape to the area of ​​the front side plate on the outer peripheral surface of the third insulating tape, and then wind the fourth winding N3. The fourth winding N3 is wound along the outer peripheral surface of the reverse-folded tape and the third insulating tape. Fold the reverse-folded tape back and apply it to the surface of the area of ​​the front side plate of the fourth winding N3. The outer peripheral surface of the fourth winding N3 is completely covered by the fourth insulating tape.

[0027] The fifth winding S2 is wound along the outer peripheral surface of the reverse folded tape and the fourth insulating tape, and the outer peripheral surface of the fifth winding S2 is completely covered by the fifth insulating tape;

[0028] The sixth winding N4 is wound along the outer peripheral surface of the fifth insulating tape, and the outer peripheral surface of the sixth winding N4 is completely covered by the sixth insulating tape.

[0029] As a preferred embodiment, the pin of the fifth PIN 5 is shortened after soldering.

[0030] Compared with the prior art, this utility model has significant advantages and beneficial effects. Specifically, as can be seen from the above technical solution, it mainly solves the problem of high cost and long delivery cycle caused by relying on redesigning molds for new products. At the same time, through the improvement of the skeleton, combined with the arrangement of the magnetic core and windings, specifically, the starting and ending wires of the fourth winding N3 are brought out from the top of the rear side plate, while the starting and ending wires of the first winding S1, the second winding N1, the third winding N2, the fifth winding S2, and the sixth winding N4 are arranged at the bottom of the front side plate. The core is connected to the corresponding first PIN 1, second PIN 2, third PIN 3, fourth PIN 4, and fifth PIN 5. The core is provided with an air gap, which is located near the front side of the first PIN 1, second PIN 2, third PIN 3, fourth PIN 4, and fifth PIN 5. This makes the transformer easy to manufacture and takes into account the electrical characteristics requirements such as inductance, leakage inductance, withstand voltage, and high voltage. For orders with small quantities and short lead times, it can quickly respond to customer needs and keep costs under control.

[0031] To more clearly illustrate the structural features and effects of this utility model, the following detailed description of this utility model is provided in conjunction with the accompanying drawings and specific embodiments. Attached Figure Description

[0032] Figure 1 This is a circuit wiring diagram of a transformer according to an embodiment of this utility model;

[0033] Figure 2 This is a partial cross-sectional view of a transformer according to an embodiment of the present invention;

[0034] Figure 3 This is a bottom view of a transformer according to an embodiment of the present utility model;

[0035] Figure 4 This is a front view of a transformer according to an embodiment of the present invention;

[0036] Figure 5 This is a right view of a transformer according to an embodiment of the present utility model;

[0037] Figure 6 This is a winding sequence diagram of the transformer according to an embodiment of the present invention;

[0038] Figure 7This is a schematic diagram of the frame structure of a transformer according to an embodiment of this utility model;

[0039] Figure 8 This is a diagram showing the electrical characteristic test results of a transformer according to an embodiment of this utility model. Detailed Implementation

[0040] Please refer to Figures 1 to 8 As shown, it illustrates the specific structure of an embodiment of the present invention.

[0041] In the description of this utility model, it should be noted that the terms "upper", "lower", "left", "right", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0042] A common type of horizontal frame is available on the market, which many manufacturers can mass-produce using mature processes. It is usually injection molded and then the pins are inserted. It is readily available on the market. It includes a front side plate, a rear side plate, and a winding cylinder integrally connected between the front side plate and the rear side plate. The winding cylinder has a magnetic core fixing hole inside, which penetrates the front side plate and the rear side plate in the front-to-back direction. The outer periphery of the winding cylinder has a winding groove located between the front side plate and the rear side plate. The bottom of the front side plate and the rear side plate each have 5 pin positions spaced lateral to lateral, for a total of 10 pin positions, which is suitable for 10-pin transformer products.

[0043] We need to produce a high-frequency transformer that requires four long pins and one short pin on one side, and no pins on the other side. Redesigning the mold to produce the frame would be costly and have a long delivery cycle. For orders with small quantities and short lead times, redesigning the mold is not a suitable option.

[0044] Based on this, a transformer is provided, which utilizes the above-mentioned horizontal frame with an improved design, eliminating the need for redesigning a new frame using a new mold. The transformer includes a frame A1, a magnetic core D2, and windings D3. Specifically:

[0045] The skeleton A1 includes a front side plate D1, a rear side plate, and a winding cylinder A5 integrally connected between the front side plate D1 and the rear side plate. The winding cylinder A5 has a magnetic core fixing hole A11 inside, which penetrates the front side plate D1 and the rear side plate in a front-to-back direction. Specifically, the magnetic core fixing hole A11 penetrates forward through the front side plate D1 and backward through the rear side plate. The outer periphery of the winding cylinder has a winding groove A6 located between the front side plate D1 and the rear side plate, providing space for winding the coil. The bottom A3 of the front side plate D1 has a first PIN position 1, a second PIN position 2, a third PIN position 3, a fourth PIN position 4, and a fifth PIN position 5 spaced apart on the left and right. The fifth pin is 5. Pins 1, 2, 3, 4, and 5 all have inserted pins. The bottom A4 of the rear panel has pins 6, 7, 8, 9, and 10 spaced out on either side. The pins at pins 6, 7, 8, 9, and 10 are removed. The front panel D1 and rear panel can have a symmetrical design. Cable guides A41 and A42 can be provided at the top and bottom of the front panel D1 and rear panel to provide cable paths and guide the starting and ending of cables. During production, a plastic skeleton is first injection molded, with several small holes pre-drilled on it. These holes correspond to pins 1-10. An automatic machine then inserts 10 pins into the corresponding holes at once. This type of frame with pins can be used as a universal frame. Its mass production allows for better cost control and meets the needs of various transformer frame options. In this utility model, only 4 pins are needed. The pins at the sixth, seventh, eighth, ninth, and tenth pins are removed. The pin at the fifth pin is shortened after soldering, without extending beyond the bottom edge of the front side plate D1.

[0046] The magnetic core D2 is inserted into the magnetic core fixing hole A11. The magnetic core D2 typically includes two E-type magnetic blocks. The central post of one E-type magnetic block extends from the front end to the rear end into the magnetic core fixing hole, and the central post of the other E-type magnetic block extends from the rear end to the front end into the magnetic core fixing hole. The mating surfaces of the two central posts are glued together. In this embodiment, an E-type magnetic block and an I-type magnetic block can also be used, with the I-type magnetic block located on the front side, close to the side where the front side plate D1 is located. An air gap can be formed between the I-type and E-type magnetic blocks, and a gasket made of non-magnetic material is placed in the air gap. After the two magnetic blocks are installed, they are fixed with multiple layers of tape. The air gap is typically between 0.1mm and 0.3mm.

[0047] The winding D3 is disposed within the winding groove A6. The winding includes a first winding S1, a second winding N1, a third winding N2, a fourth winding N3, a fifth winding S2, and a sixth winding N4, which are wound radially outward from the outer periphery of the winding drum. Each winding is coaxially wound and clockwise. The starting pin of the first winding S1 is the second pin 2, and the ending pin is NC. The starting pin of the second winding N1 is the third pin 3, and the ending pin is the fifth pin 5. The starting pin of the third winding N2 is the fourth pin 4, and the ending pin is the first pin 1. The fourth winding N3... Using TIW-B wire, the starting pin is S and the ending pin is F; the starting pin of the fifth winding S2 is 1 and the ending pin is NC; the starting pin of the sixth winding N4 is the fifth pin 5 and the ending pin is the second pin 2; preferably, Teflon sleeves are provided on both the starting and ending pins of the fourth winding N3, and Teflon sleeves are also provided on the ending pin of the sixth winding N4; when the first winding S1 is wound, it can be directly wound along the outer peripheral wall of the winding drum. Since the winding drum extends in the front-to-back direction, the first winding S1 is wound one layer along the winding drum. The outer surface of the first winding S1 is covered with a first insulating tape, usually a full cover, meaning the entire outer surface of the first winding S1 is covered by the first insulating tape. The second winding N1 is wound along the outer surface of the first insulating tape, also with one layer, and the outer surface of the second winding N1 is completely covered by the second insulating tape. The third winding N2 is wound along the outer surface of the second insulating tape, with two layers, and the outer surface of the third winding N2 is completely covered by the third insulating tape. Before winding the fourth winding N3, a reverse-folded tape A2 is applied to the area near the front side plate D1 on the outer surface of the third insulating tape, covering the area of ​​the fourth winding N3. The third insulating tape is at least 3 mm thick, meaning that the folded tape A2 covers at least 3 mm (front and back width) of the coil of the third winding N2. Then, it is wound around the fourth winding N3. The fourth winding N3 is wound along the outer circumferential surface of the folded tape A2 and the third insulating tape, with two layers. The outer circumferential surface of the fourth winding N3 is completely covered by the fourth insulating tape. Then, the folded tape A2 is folded back and attached to the surface of the front side plate D1 of the fourth winding N3, similarly covering at least 3 mm (front and back width) of the coil of the fourth winding N3. Alternatively, the folded tape A2 can be folded back and attached to the surface of the fourth winding N3 first, and then the fourth insulating tape can be wrapped around it. The fifth winding S2 is wound along the outer circumferential surface of the reverse folded tape A2 and the fourth insulating tape, with one layer of winding, and the outer circumferential surface of the fifth winding S2 is completely covered by the fifth insulating tape; the sixth winding N4 is wound along the outer circumferential surface of the fifth insulating tape, with one layer of winding, and the outer circumferential surface of the sixth winding N4 is completely covered by the sixth insulating tape.The starting and ending wires of the fourth winding N3 are flying wires, which emerge from the top of the rear side plate. The starting wire is threaded through a white Teflon sleeve, and the ending wire is threaded through a black Teflon sleeve for easy identification. Typically, the flying wire needs to be stranded and tinned.

[0048] A first adhesive tape is wrapped around the bottom of the rear side panel. The width of the first adhesive tape extends beyond the bottom of the rear side panel and extends to the rear of the rear side panel. Then, the tape portion at the rear is folded upwards to the rear side of the rear side panel and bonded in place. Then, a second adhesive tape is wrapped around the outer periphery of the magnetic core, that is, along the rear side of the rear side panel, the left side of the magnetic core, the front side of the front side panel D1, and the right side of the magnetic core, and then back to the rear side of the rear side panel. This process is repeated, and the second adhesive tape is bonded to the outer surface of the first adhesive tape.

[0049] During production and assembly, the pins of the sixth, seventh, eighth, ninth, and tenth pins of the general-purpose frame are first removed. Then, the windings are wound, and then the magnetic cores are installed, for example, E-type and I-type magnetic cores are assembled. Then, the first tape is wrapped, and then the second tape is wrapped. The starting and ending wires of each winding are soldered to the corresponding pins. The pin of the fifth pin needs to be shortened after soldering.

[0050] like Figure 6 As shown, it displays the winding sequence, including the starting and ending wires of each winding, the selected wire material, and provides a winding coil count, along with technical information such as the number of tape turns covering the outer periphery of each winding. Figure 8 The electrical characteristic test results of the transformer according to an embodiment of the present invention are shown. The transformer product obtained by adopting this structure meets the specifications in terms of inductance, leakage inductance, withstand voltage and high voltage.

[0051] The key design feature of this invention is that it effectively solves the problem of high costs and long delivery cycles caused by redesigning molds for new products. Furthermore, through improvements to the frame and the arrangement of the magnetic core and windings—specifically, the starting and ending wires of the fourth winding N3 emerge from the top of the rear side plate, while the starting and ending wires of the first winding S1, second winding N1, third winding N2, fifth winding S2, and sixth winding N4 are arranged at the bottom of the front side plate to connect to the corresponding first PIN 1, second PIN 2, third PIN 3, fourth PIN 4, and fifth PIN 5—and the magnetic core has an air gap located near the front of the first PIN 1, second PIN 2, third PIN 3, fourth PIN 4, and fifth PIN 5. This design makes the transformer easier to manufacture, accommodates electrical characteristics such as inductance, leakage inductance, withstand voltage, and high voltage, and allows for rapid response to customer needs for orders with relatively small quantities and short lead times, while maintaining controllable costs.

[0052] The above description is merely a preferred embodiment of the present utility model and does not constitute any limitation on the technical scope of the present utility model. Therefore, any minor modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present utility model shall still fall within the scope of the technical solution of the present utility model.

Claims

1. A transformer, characterized in that, Including: The frame includes a front side plate, a rear side plate, and a winding cylinder integrally connected between the front side plate and the rear side plate. The winding cylinder has a magnetic core fixing hole inside, which penetrates the front side plate and the rear side plate in the front-rear direction. The outer periphery of the winding cylinder has a winding groove located between the front side plate and the rear side plate. The bottom of the front side plate has a first PIN, a second PIN, a third PIN, a fourth PIN, and a fifth PIN at left and right intervals. The first PIN, the second PIN, the third PIN, and the fourth PIN all retain a pin. The fifth PIN is shortened and does not extend beyond the bottom end face of the front side plate. A magnetic core is inserted into a fixing hole; the magnetic core is provided with an air gap, which is located near the front side of the first PIN, second PIN, third PIN, fourth PIN, and fifth PIN. The winding is disposed in the winding groove. The winding includes a first winding S1, a second winding N1, a third winding N2, a fourth winding N3, a fifth winding S2, and a sixth winding N4, which are wound radially outward from the outer periphery of the winding drum. The starting and ending wires of the fourth winding N3 emerge from the top of the rear side plate. The starting and ending wires of the first winding S1, the second winding N1, the third winding N2, the fifth winding S2, and the sixth winding N4 are arranged at the bottom of the front side plate to connect to the corresponding first PIN, second PIN, third PIN, fourth PIN, and fifth PIN.

2. A transformer according to claim 1, characterized in that, The bottom of the rear panel is provided with a sixth PIN, a seventh PIN, an eighth PIN, a ninth PIN, and a tenth PIN at left and right intervals. The pins of the sixth PIN, the seventh PIN, the eighth PIN, the ninth PIN, and the tenth PIN are removed.

3. A transformer according to claim 1, characterized in that, The magnetic core includes an E-shaped magnetic block and an I-shaped magnetic block. The central column of the E-shaped magnetic block extends from the rear end to the front end into the fixing hole of the magnetic core. The I-shaped magnetic block is assembled with the front end of the E-shaped magnetic block, and the air gap is formed between the I-shaped magnetic block and the E-shaped magnetic block.

4. A transformer according to claim 3, characterized in that, The air gap is lined with a gasket made of non-magnetic material.

5. A transformer according to claim 3, characterized in that, The front end face of the central column of the E-type magnetic block is glued and fixed to the center of the rear end face of the I-type magnetic block.

6. A transformer according to claim 1, characterized in that, The starting pin of the first winding S1 is the second pin, and the ending pin is NC; The starting pin of the second winding N1 is the third pin, and the ending pin is the fifth pin. The starting pin of the third winding N2 is the fourth pin, and the ending pin is the first pin. The starting pin of the fourth winding N3 is S, and the ending pin is F; The starting pin of the fifth winding S2 is , and the ending pin is NC; The starting pin of the sixth winding N4 is the fifth pin, and the ending pin is the second pin.

7. A transformer according to claim 1, characterized in that, The starting and ending wires of the fourth winding N3 are both fitted with a first Teflon sleeve.

8. A transformer according to claim 1 or 7, characterized in that, The tail wire of the sixth winding N4 is also fitted with a second Teflon sleeve.

9. A transformer according to claim 1, characterized in that, The first winding S1 is wound along the outer peripheral wall of the winding drum, and the outer peripheral surface of the first winding S1 is completely covered with the first insulating tape. The second winding N1 is wound along the outer peripheral surface of the first insulating tape, and the outer peripheral surface of the second winding N1 is completely covered by the second insulating tape; The third winding N2 is wound along the outer peripheral surface of the second insulating tape, and the outer peripheral surface of the third winding N2 is completely covered by the third insulating tape; Before winding the fourth winding N3, apply a reverse-folded tape to the area of ​​the front side plate on the outer peripheral surface of the third insulating tape, and then wind the fourth winding N3. The fourth winding N3 is wound along the outer peripheral surface of the reverse-folded tape and the third insulating tape. Fold the reverse-folded tape back and apply it to the surface of the area of ​​the front side plate of the fourth winding N3. The outer peripheral surface of the fourth winding N3 is completely covered by the fourth insulating tape. The fifth winding S2 is wound along the outer peripheral surface of the reverse folded tape and the fourth insulating tape, and the outer peripheral surface of the fifth winding S2 is completely covered by the fifth insulating tape; The sixth winding N4 is wound along the outer peripheral surface of the fifth insulating tape, and the outer peripheral surface of the sixth winding N4 is completely covered by the sixth insulating tape.

10. A transformer according to claim 1, characterized in that, The pin of the fifth PIN 5 is cut short after soldering.

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