Small-size high-power-density transformer
By adopting a primary coil with a three-layer insulated wire disc structure and a secondary coil with a PCB board structure, combined with a frameless design, the problem of low modularity and automation in small-volume transformer design has been solved, enabling the production of transformers with high power density and high reliability.
Patent Information
- Application Number
- CN202423061253.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-11
- Publication Date
- 2025-11-11
- Estimated Expiration
- 2034-12-11
AI Technical Summary
Existing transformers suffer from low modularity and automation, inconsistent material usage, and poor space compactness in small-volume designs, resulting in high production costs and difficulty in achieving high reliability.
The primary coil, consisting of a coil disc structure made of three layers of insulated wire, and the secondary coil, consisting of a PCB board structure, are combined with a frameless design and fixed by a dispensing process to achieve modular production and automated processing.
This enables a modular design for small-volume, high-power-density transformers, reducing production costs, improving production efficiency and reliability, and reducing reliance on manual labor and auxiliary materials.
Smart Images
Figure CN223539433U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of transformers, specifically to a small-volume, high-power-density transformer. Background Technology
[0002] The application scenarios of industrial power supplies have evolved from the initial large and crude to the current small and sophisticated, requiring high reliability, small size, modularity, standardization, and universality. Despite the integration of different technology sources and supply chain systems, most products are still relatively expensive and require a lot of manpower to produce, failing to achieve the desired results. Meanwhile, industrial equipment is developing rapidly and has been applied to equipment in people's lives and medical fields. Currently, the common structures still require a lot of auxiliary processing and materials, resulting in poor consistency and space compactness.
[0003] In summary, the current progress of transformers in terms of size is trending towards modularization and automation.
[0004] To address the aforementioned issues, we have made a series of improvements. Utility Model Content
[0005] The purpose of this invention is to provide a small-volume, high-power-density transformer to overcome the aforementioned shortcomings and deficiencies of the existing technology.
[0006] A small-volume, high-power-density transformer includes: a first magnetic core, a base, a primary coil, a secondary coil, a second magnetic core, and copper nails. The base, primary coil, secondary coil, and second magnetic core are sequentially connected to the first magnetic core. The primary coil consists of three sets, and the secondary coil consists of two sets. The secondary coil is connected to the base via copper nails.
[0007] The primary coil is composed of three layers of insulated wire, the primary coil has a coil structure, and the secondary coil has a PCB board structure.
[0008] Furthermore, the base includes: a substrate, a substrate hole, a nail slot, and pins. The substrate hole is located in the center of the substrate and is connected to the first magnetic core. The nail slot is located at the bottom of the substrate and is connected to a copper nail. The pins are located at the top of the substrate.
[0009] Furthermore, the secondary coil has a frame-shaped structure, and a connection hole is provided below the secondary coil, which is connected to a copper nail.
[0010] The beneficial effects of this utility model are:
[0011] Compared with traditional technology, the primary coil of this invention adopts a coil structure composed of three layers of insulated wire, which is a modular structure and does not require manual winding; the secondary coil adopts a PCB board structure design, which does not require auxiliary materials or manual processing; and it does not require a frame, making the design flexible. Attached Figure Description
[0012] Figure 1 This is a schematic diagram of the structure of this utility model.
[0013] Figure 2 This is an exploded view of the present invention.
[0014] Figure label:
[0015] The components include a first magnetic core 100, a base 200, a substrate 210, a substrate hole 220, a pin slot 230, and a pin 240.
[0016] Primary coil 300, secondary coil 400 and connecting hole 410.
[0017] The second magnetic core 500 and the copper nail 600. Detailed Implementation
[0018] The present invention will be further described below with reference to specific embodiments. It should be understood that the following embodiments are for illustrative purposes only and are not intended to limit the scope of the present invention.
[0019] Figure 1 This is a schematic diagram of the structure of this utility model. Figure 2 This is an exploded view of the present invention.
[0020] Example 1
[0021] like Figure 1-2 As shown, a small-volume, high-power-density transformer includes: a first magnetic core 100, a base 200, a primary coil 300, a secondary coil 400, a second magnetic core 500, and copper nails 600. The base 200, primary coil 300, secondary coil 400, and second magnetic core 500 are sequentially connected to the first magnetic core 100. There are 3 sets of primary coils 300 and 2 sets of secondary coils 400. The secondary coils 400 are connected to the base 200 via copper nails 600.
[0022] The primary coil 300 is composed of three layers of insulated wire and has a coil structure, while the secondary coil 400 has a PCB board structure.
[0023] The base 200 includes: a substrate 210, a substrate hole 220, a nail slot 230, and a pin 240. The substrate hole 220 is located in the center of the substrate 210 and is connected to the first magnetic core 100. The nail slot 230 is located at the bottom of the substrate 210 and is connected to the copper nail 600. The pin 240 is located at the top of the substrate 210.
[0024] The secondary coil 400 has a frame structure, and a connection hole 410 is provided below the secondary coil 400. The connection hole 410 is connected to the copper nail 600.
[0025] The innovation of this utility model is reflected in:
[0026] 1. Improvements to the primary coil 300. The primary coil adopts a coil structure composed of three layers of insulated wire. First, it can be pre-produced before assembly, eliminating the need for traditional manual winding. Second, the coil structure eliminates the need for tape and sleeves for fixation.
[0027] 2. Improvements to the secondary coil 400. The secondary coil 400 is designed as a PCB board structure. First, it is also a modular frame structure that can be prefabricated automatically. Second, the connecting hole 410 at the bottom is used to connect with the copper nail 600, facilitating the connection of the overall structure. Third, no auxiliary materials or manual labor are required. Fourth, the PCB board connection uses a high-frequency soldering process, ensuring high reliability.
[0028] 3. The overall structural design eliminates the traditional skeleton structure, is not limited by the skeleton structure, and can be flexibly transformed.
[0029] 4. The primary coil 300, secondary coil 400, first magnetic core 100, and second magnetic core 500 are fixed together using a dispensing process, ensuring strong adhesion. No varnish impregnation is required.
[0030] Compared with traditional technology, the primary coil of this invention adopts a coil structure composed of three layers of insulated wire, which is a modular structure and does not require manual winding; the secondary coil adopts a PCB board structure design, which does not require auxiliary materials or manual processing; and it does not require a frame, making the design flexible.
[0031] The specific embodiments of this utility model have been described above, but this utility model is not limited thereto. Various changes can be made to this utility model as long as they do not depart from its spirit.
Claims
1. A small-volume, high-power-density transformer, characterized in that, include: The system comprises a first magnetic core (100), a base (200), a primary coil (300), a secondary coil (400), a second magnetic core (500), and a copper nail (600). The base (200), primary coil (300), secondary coil (400), and second magnetic core (500) are sequentially connected to the first magnetic core (100). There are three sets of primary coils (300) and two sets of secondary coils (400). The secondary coils (400) are connected to the base (200) via copper nails (600). The primary coil (300) is composed of three layers of insulated wire, the primary coil (300) has a coil structure, and the secondary coil (400) has a PCB board structure.
2. The small-volume, high-power-density transformer according to claim 1, characterized in that, The base (200) includes: a substrate (210), a substrate hole (220), a nail slot (230), and a pin (240). The substrate hole (220) is located in the center of the substrate (210) and is connected to the first magnetic core (100). The nail slot (230) is located at the bottom of the substrate (210) and is connected to the copper nail (600). The pin (240) is located at the top of the substrate (210).
3. A small-volume, high-power-density transformer according to claim 1, characterized in that, The secondary coil (400) has a frame structure, and a connecting hole (410) is provided below the secondary coil (400). The connecting hole (410) is connected to a copper nail (600).