Multi-groove transformer framework with gradually-changed perimeter
By designing a multi-slot gradient perimeter and optimizing the insulation partition, the problems of insulation breakdown and heat dissipation of the transformer frame under high voltage conditions were solved, realizing the miniaturization and efficient winding of the transformer, and improving space utilization and electrical performance.
Patent Information
- Application Number
- CN202522205025.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-20
- Publication Date
- 2025-11-25
- Estimated Expiration
- 2035-10-20
AI Technical Summary
Traditional transformer frames are prone to insulation breakdown and short circuits under high voltage conditions. The frames are bulky, the windings are loosely distributed, which is not conducive to heat dissipation, and the utilization rate of slot space is low.
The design employs a multi-slot gradually changing perimeter design, dividing the primary winding area into multiple sequentially arranged primary winding slots. The perimeter inside the slot cavity gradually decreases from the high-voltage input end to the low-voltage ground end. Combined with the design of insulating partitions and pins, the winding distribution and voltage gradient matching are optimized.
It improves insulation reliability, reduces electric field stress, enables transformer miniaturization and efficient heat dissipation, and enhances slot space utilization and winding efficiency.
Smart Images
Figure CN223598527U_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The utility model relates to transformer framework technical field especially relates to a transformer framework of many groove gradual change perimeter. BACKGROUND
[0002] As the core supporting component of the transformer, the structure design of the transformer framework is directly related to the electrical performance, production efficiency and reliability of the transformer. With the development of the switching power supply towards high frequency and high power density, higher requirements are put forward for the working voltage and insulation reliability of the transformer. However, when the traditional transformer framework is used in a high-voltage environment, the primary winding is usually wound in a single winding slot with equal perimeter.
[0003] This single slot structure has many significant disadvantages. First, when the primary winding is subjected to high voltage, there is a very high potential difference between the starting end and the ending end of the winding, which increases the distributed capacitance between the adjacent turns and layers of the winding, and the electric field stress is highly concentrated, which is prone to insulation breakdown short circuit, seriously threatening the safety of the whole machine. Secondly, in order to meet the safety creepage distance requirements of high-voltage insulation, it is often necessary to increase the slot width or use thicker insulation wall thickness, which leads to a large volume of the framework, which is contrary to the development trend of modern electronic equipment miniaturization and lightweight. Furthermore, the single wide slot makes the winding distribution loose, which is not conducive to heat dissipation, and the wire package is prone to collapse during the winding process, affecting product consistency and production efficiency.
[0004] To solve the above problems, some schemes using multi-slot design to disperse high voltage have appeared in the prior art. However, these schemes usually simply separate the long slot into multiple short slots with the same depth and perimeter. This uniform design does not fully consider the continuous decreasing characteristic of voltage distribution along the winding, resulting in low space utilization of the winding slot at the low-voltage end, which limits the further improvement of the transformer power density. In view of the above problems, the prior art needs to be improved. UTILITY MODEL CONTENTS
[0005] The utility model aims at solving the technical problems of the existing transformer framework used in high-voltage environment, such as easy insulation breakdown short circuit of the primary winding, large volume of the framework, loose winding distribution not conducive to heat dissipation, and low space utilization of the winding slot, and proposes a transformer framework with multiple slots and gradually changing perimeter.
[0006] To achieve the above purpose, the utility model adopts the technical scheme that a transformer framework with multiple slots and gradually changing perimeter comprises a framework body made of insulating material, and further comprises:
[0007] A winding column is arranged on the framework body, and the winding column sequentially comprises a primary winding region and a secondary winding region along its axial direction.
[0008] The primary winding area is divided into a plurality of sequentially arranged primary winding slots, and the secondary winding area is provided with a secondary winding slot.
[0009] The first pin, as a high-voltage input end of the primary winding, is electrically connected to the starting end of the first primary winding slot.
[0010] The second pin, as a low-voltage grounding end of the primary winding, is electrically connected to the ending end of the last primary winding slot.
[0011] The internal circumferences of the plurality of sequentially arranged primary winding slots gradually decrease from the high-voltage input end to the low-voltage grounding end, so as to increase the number of winding turns.
[0012] Further, according to the above technical solution, the gradient of the internal circumferences of the plurality of primary winding slots gradually decreasing is uniform.
[0013] More specifically, in some embodiments, the gradient of the internal circumferences of the plurality of primary winding slots gradually decreasing is non-uniform, and the gradient of the internal circumferences gradually decreasing matches the voltage drop gradient on the primary winding.
[0014] Preferably, according to the above technical solution, the secondary winding slot is located at one end of the winding column close to the second pin.
[0015] In some embodiments, according to the above technical solution, an insulating partition plate is arranged between every two adjacent primary winding slots on the skeleton body, and the height of the insulating partition plate is higher than the winding height.
[0016] Further, according to the above technical solution, the insulating partition plate is provided with an opening for the winding wire between adjacent primary winding slots to pass through.
[0017] Preferably, according to the above technical solution, the edge of the opening is rounded or polished to form a smooth guiding surface without stress concentration.
[0018] In some embodiments, according to the above technical solution, a rectangular hole is formed in the middle of the skeleton body for inserting an iron core.
[0019] Preferably, according to the above technical solution, the skeleton body is provided with a first end plate and a second end plate, the first pin is arranged on the first end plate, the second pin is arranged on the second end plate, and the secondary winding slot is separated from the primary winding slot by the second end plate.
[0020] In some embodiments, according to the above technical solution, the skeleton body is further provided with two secondary winding pins for electrically connecting the two ends of the winding of the secondary winding slot.
[0021] Compared with the prior art, the present application has the following beneficial effects:
[0022] I. This utility model divides the primary winding area into multiple sequentially arranged primary winding slots, and sets a first pin as a high-voltage input terminal electrically connected to the first primary winding slot, and a second pin as a low-voltage ground terminal electrically connected to the last primary winding slot. This multi-slot design can effectively disperse high voltage, reduce the potential difference and electric field stress between the start and end of the winding, as well as between adjacent turns and layers, thereby significantly improving insulation reliability and avoiding insulation breakdown.
[0023] II. This utility model innovatively designs multiple primary edge slots with their internal circumference gradually decreasing from the high-voltage input end to the low-voltage grounding end, while the slot depth gradually increases from the high-voltage input end to the low-voltage grounding end. This design of gradually changing circumference and depth fully considers the continuous decreasing characteristics of voltage distribution along the winding, enabling tighter winding of the coil while ensuring insulation safety, thus improving the space utilization of the slots. Compared with traditional equal-circumference slots, this utility model can accommodate more winding coils at the low-voltage end, thereby achieving a smaller frame volume at the same power density, meeting the trend of miniaturization and lightweighting of modern electronic devices.
[0024] Third, the multi-slot design of this utility model, combined with the gradual circumference, allows the windings to be more closely distributed in each slot, improving the heat dissipation of the windings, while avoiding coil collapse, and improving winding efficiency and product consistency.
[0025] In summary, the multi-slot gradually changing perimeter transformer frame of this utility model, through its ingenious structural design, effectively solves the problems of high-voltage insulation breakdown, large frame volume, poor heat dissipation, and low utilization rate of slot space in the prior art, and has significant technological progress and beneficial effects. Attached Figure Description
[0026] Fig. 1 This is a front view of the present utility model;
[0027] Fig. 2 This is a schematic diagram of the overall structure of this utility model.
[0028] In the figure: 1. Skeleton body; 2. Winding post; 3. Primary side wire groove; 4. Secondary side wire groove; 5. First pin; 6. Second pin; 7. Insulating partition; 701. Opening; 8. Rectangular hole. Detailed Implementation
[0029] The following description is intended to disclose the present invention so that those skilled in the art can implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art.
[0030] like Figs. 1-2 The transformer frame shown includes a frame body 1 made of insulating material, and further includes:
[0031] The winding post 2 is arranged on the framework body 1, and the winding post 2 is sequentially provided with a primary winding area and a secondary winding area along its axial direction;
[0032] The primary winding area is divided into a plurality of sequentially arranged primary winding slots 3, and the secondary winding area is provided with a secondary winding slot 4;
[0033] The first pin 5 is electrically connected to the starting end of the first primary winding slot 3 as the high-voltage input end of the primary winding;
[0034] The second pin 6 is electrically connected to the ending end of the last primary winding slot 3 as the low-voltage grounding end of the primary winding;
[0035] The internal circumferences of the plurality of sequentially arranged primary winding slots 3 gradually decrease from the high-voltage input end to the low-voltage grounding end, for increasing the number of winding turns.
[0036] Specifically, the framework body 1 is the basic structure of the entire transformer framework, which is usually made of plastic or composite material with high temperature resistance and high insulation performance, such as phenolic resin, epoxy resin, etc. Its main function is to provide mechanical support and ensure electrical insulation between windings. The winding post 2 is arranged on the framework body 1, which is the core component for winding the primary winding and the secondary winding. The winding post 2 is divided into two main areas along its axial direction: the primary winding area and the secondary winding area. This zoning design helps to effectively isolate the high-voltage primary winding from the low-voltage secondary winding, thereby improving the overall insulation performance and safety.
[0037] The "primary winding area" is the part of the winding post 2 for winding the primary winding, which is divided into a plurality of sequentially arranged "primary winding slots 3". These primary winding slots 3 are grooves for accommodating the primary winding, and their number and arrangement are designed to disperse high voltage and reduce the potential difference within a single slot. The "secondary winding area" is the part of the winding post 2 for winding the secondary winding, which is provided with a "secondary winding slot 4". The secondary winding slot 4 is used to accommodate the secondary winding, maintaining a certain insulation distance from the primary winding area.
[0038] In order to realize the electrical connection of the primary winding, the first pin 5 and the second pin 6 are provided in this embodiment, wherein the first pin 5 is electrically connected to the starting end of the first primary winding slot 3 as the high-voltage input end of the primary winding, which means that the high-voltage current will enter the winding of the first primary winding slot 3 from the first pin 5, and the second pin 6 is electrically connected to the ending end of the last primary winding slot 3 as the low-voltage grounding end of the primary winding, so that the primary winding forms a complete series circuit with the current flowing from the high-voltage input end to the low-voltage grounding end.
[0039] The core innovation of the embodiment is that the internal circumferences of the slot cavities of the plurality of sequentially arranged primary side wire slots 3 gradually decrease from the high-voltage input end to the low-voltage grounding end, and the depths of the slot cavities of the plurality of primary side wire slots 3 gradually increase from the high-voltage input end to the low-voltage grounding end. This design makes the voltage on the winding gradually decrease from the high-voltage input end to the low-voltage grounding end, and the physical space structure (circumference, depth) of the skeleton body 1 can adaptively change with the change of voltage and current, thereby realizing graded insulation and gradient matching. Specifically, the internal circumferences of the slot cavities of the primary side wire slots 3 gradually decrease, which means that the first primary side wire slot 3 close to the high-voltage input end has a larger circumference, and the last primary side wire slot 3 close to the low-voltage grounding end has a smaller circumference. This design allows fewer turns to be wound at the high-voltage end and more turns to be wound at the low-voltage end, thereby maximizing the number of winding turns and improving the power density under the premise of ensuring insulation safety. For example, at the high-voltage input end, because the voltage is high, a larger creepage distance is required, and therefore the slot cavity has a larger circumference to provide sufficient insulation space. As the voltage gradually decreases, the requirement for the creepage distance also decreases, and the slot cavity circumference can be correspondingly reduced, thereby more effectively utilizing the space.
[0040] When the transformer skeleton with the plurality of slots with gradually changing circumferences is used, high-frequency alternating current flows in from the first pin 5 as the high-voltage input end, passes through the primary winding in the plurality of primary side wire slots 3 connected in series, and then flows out from the second pin 6 as the low-voltage grounding end. In this process, the voltage on the primary winding gradually decreases from the high-voltage end to the low-voltage end. Because the internal circumferences of the slot cavities of the primary side wire slots 3 gradually decrease from the high-voltage input end to the low-voltage grounding end, and the slot cavity depths gradually increase from the high-voltage input end to the low-voltage grounding end, the high voltage is decomposed to the plurality of primary side wire slots 3 for step-by-step processing, thereby greatly reducing the potential difference between each adjacent wire slot and greatly reducing the electric field strength required to be borne by the turns and layers, thereby fundamentally eliminating the risk of insulation breakdown. At the same time, this gradient matching design allows the number of winding turns to be increased at the low-voltage end, thereby improving the wire slot space utilization and further improving the power density of the transformer. The secondary winding is wound in the secondary side wire slot 4 to achieve energy transmission through electromagnetic induction. The design of the entire skeleton makes the transformer small, light, and efficient under the premise of ensuring high-voltage safety.
[0041] As an embodiment of the present application, the gradient of the internal circumferences of the slot cavities of the plurality of primary side wire slots 3 gradually decreases is uniform.
[0042] The "uniformly decreasing gradient" refers to that the difference between the inner circumferences of the cavities of the adjacent primary side wire slots 3 is constant. Specifically, if the primary side wire slots 3 are numbered as the first primary side wire slot, the second primary side wire slot,..., and the Nth primary side wire slot in sequence from the high-voltage input end to the low-voltage grounding end, the differences between the circumferences of the first and second primary side wire slots, the second and third primary side wire slots, and the N-1th and Nth primary side wire slots are all equal. This uniformly decreasing gradient can be achieved by accurately designing the geometric shape of the skeleton body 1, for example, by accurately controlling the mold during the manufacturing process to ensure that the size change of each primary side wire slot 3 conforms to the preset linear relationship.
[0043] The scheme of the present application can make the winding space be more evenly utilized by setting the inner circumferences of the cavities of the plurality of primary side wire slots 3 as a uniformly decreasing gradient. When the circumference decreases at a uniform gradient, the number of winding turns of each wire slot 3 can increase at a relatively stable ratio, thereby avoiding the situation that some wire slots 3 are under-wound or overloaded due to uneven changes in circumference. This uniform decrease in circumference helps to achieve smoother voltage distribution and more uniform current density in the entire primary side winding area, thereby optimizing the overall electrical performance of the transformer.
[0044] As an embodiment of the present application, the gradient of the decrease in the inner circumferences of the cavities of the plurality of primary side wire slots 3 is non-uniform, and the decreasing gradient matches the voltage drop gradient on the primary side winding. Thus, the increase in the number of winding turns is more consistent with the actual demand for voltage drop, further optimizing the performance of the transformer.
[0045] The gradient of the decrease in the inner circumferences of the cavities of the plurality of primary side wire slots 3 is non-uniform, which means that the difference in circumference between adjacent primary side wire slots 3 is not constant, but varies according to a specific rule. This non-uniform decreasing gradient can be matched according to the voltage drop gradient on the primary side winding. The voltage drop gradient refers to the rate of voltage drop at different positions on the primary side winding as the current flows. By matching the circumference decrease gradient with the voltage drop gradient, the decrease in the inner circumference of the cavity can be more significant in the area where the voltage drop is larger, so that more winding turns can be accommodated in that area; and in the area where the voltage drop is smaller, the decrease in circumference is relatively flat.
[0046] The scheme of the present application can more accurately control the number of winding turns of each primary side slot 3 by setting the gradient of the internal perimeter of the slot cavity of the plurality of primary side slots 3 to be non-uniform and matching it with the voltage drop gradient on the primary side winding. Specifically, in the area where the voltage drop on the primary side winding is larger, more winding turns are usually required to provide sufficient induced electromotive force or withstand higher voltage stress due to the need to withstand higher voltage difference. By making the internal perimeter of the slot cavity in this area decrease more, the winding space in this area can be effectively increased, thereby allowing more winding turns. On the contrary, in the area where the voltage drop is smaller, the demand for winding turns is relatively low, and a smaller perimeter decrease gradient can be used at this time to avoid unnecessary space waste. This matching mechanism makes the distribution of the winding more reasonable, fully utilizes the winding space of the skeleton body 1, and optimizes the performance of the transformer in different voltage areas.
[0047] As an embodiment of the present application, the secondary side slot 4 is located at one end of the winding column 2 close to the second pin 6.
[0048] It should be noted that by setting the secondary side slot 4 at one end of the winding column 2 close to the second pin 6, the structural layout of the transformer can be optimized, the coupling between windings can be reduced, thereby reducing leakage inductance and improving the efficiency and performance of the transformer. In addition, this layout can also flexibly adjust the positional relationship between the primary side winding and the secondary side winding according to actual application requirements, meeting the needs of different application scenarios.
[0049] As an embodiment of the present application, an insulating partition plate 7 is arranged between each two adjacent primary side slots 3 on the skeleton body 1, and the height of the insulating partition plate 7 is higher than the winding height.
[0050] The insulating partition plate 7 is a separation structure arranged between adjacent primary side slots 3, and its main function is to separate adjacent primary side slots 3 in space to prevent contact or short circuit between winding wires. The height of the insulating partition plate 7 is higher than the winding height, which means that the insulating partition plate 7 can completely cover the winding wires in the primary side slot 3, thereby providing more reliable insulation protection and effectively preventing short circuit between windings of adjacent primary side slots 3, improving the insulation performance and safety of the transformer. As a preferred embodiment, the insulating partition plate 7 can be made of the same insulating material as the skeleton body 1, such as plastic, ceramic, etc. In addition, the shape and size of the insulating partition plate 7 can be adjusted according to actual needs to adapt to different specifications of the transformer skeleton.
[0051] As an embodiment of the present application, the insulating partition plate 7 is provided with an opening 701 for the winding wires between adjacent primary side slots 3 to pass through.
[0052] Specifically, the height of the insulation partition plate 7 is set to be higher than the winding height, so as to ensure that even if there is deviation or looseness in the winding process, the winding wire will not pass over the insulation partition plate 7, thereby avoiding the risk of direct contact and short circuit between adjacent wire slots. The position and size of the opening 701 can be adjusted according to the actual winding requirements to ensure that the winding can pass through smoothly, while the overall insulation performance of the insulation partition plate 7 is not affected.
[0053] As an embodiment of the present application, the edge of the opening 701 is rounded or polished to form a smooth guiding surface without stress concentration.
[0054] The scheme of the present application eliminates sharp corners by rounding or polishing the edge of the opening 701, forming a smooth guiding surface. When the winding wire passes through the opening 701, the stress can be dispersed due to the smooth guiding surface, thereby avoiding the occurrence of stress concentration phenomenon. This can effectively protect the insulation layer of the winding wire, reduce the risk of winding wire damage, and improve the electrical performance and reliability of the transformer.
[0055] As an embodiment of the present application, a rectangular hole 8 is provided in the middle of the framework body 1 for inserting the iron core.
[0056] The rectangular hole 8 refers to a through hole with a rectangular cross section reserved in the central region of the framework body 1, which is matched in size and shape with the used iron core, so that the iron core can pass through smoothly and be fixed on the framework body 1.
[0057] As an embodiment of the present application, the framework body 1 is provided with a first end plate and a second end plate, the first lead 5 is arranged on the first end plate, the second lead 6 is arranged on the second end plate, and the secondary side wire slot 4 is separated from the primary side wire slot 3 by the second end plate.
[0058] Specifically, the first end plate and the second end plate are respectively located at both ends of the framework body 1, providing physical support for the arrangement of the first lead 5 and the second lead 6. The first lead 5 and the second lead 6 are arranged on the first end plate and the second end plate respectively, which makes the input and output ends of the primary side winding separate in space, which is conducive to optimizing the circuit layout and reducing electromagnetic interference. The secondary side wire slot 4 is separated from the primary side wire slot 3 by the second end plate, which can effectively prevent the short circuit risk between the primary side winding and the secondary side winding and improve the safety of the transformer.
[0059] As an embodiment of the present application, the framework body 1 is further provided with two secondary side leads for electrically connecting the two ends of the winding of the secondary side wire slot 4.
[0060] By setting the auxiliary side pin on the skeleton body 1, the end of the auxiliary side winding can be directly connected to the pin without additional connecting wires or other complex connection methods. This way not only simplifies the assembly process, improves production efficiency, but also helps to reduce the connection resistance, thereby improving the overall electrical performance of the transformer. In addition, by optimizing the position and structure of the auxiliary side pin, the heat dissipation performance and anti-interference ability of the transformer can be further improved.
[0061] The basic principle, main features and advantages of the present application are shown and described above. Those skilled in the art should understand that the present application is not limited by the above examples, and the above examples and descriptions in the specification are only the principles of the present application. Without departing from the spirit and scope of the present application, various changes and improvements can be made to the present application, and these changes and improvements all fall within the scope of the claimed present application. The scope of protection required by the present application is defined by the appended claims and their equivalents.
Claims
1. A transformer frame with a multi-slot gradually varying perimeter, comprising a frame body (1) made of insulating material, characterized in that, Also includes: A winding post (2) is disposed on the skeleton body (1), and the winding post (2) is provided with a primary winding area and a secondary winding area in sequence along its axial direction; The primary winding region is divided into multiple primary winding slots (3) arranged in sequence, and the secondary winding region is provided with a secondary winding slot (4). The first pin (5) serves as the high-voltage input terminal of the primary winding and is electrically connected to the starting end of the first primary winding slot (3). The second pin (6) serves as the low-voltage grounding terminal of the primary winding and is electrically connected to the end of the last primary winding slot (3). The circumference of the cavity of the multiple sequentially arranged primary edge grooves (3) decreases gradually from the high voltage input end to the low voltage grounding end, which is used to increase the number of winding coils.
2. The transformer frame with a multi-slot gradually varying perimeter according to claim 1, characterized in that, The gradient of decreasing perimeter inside the cavity of the multiple original edge grooves (3) is uniform.
3. The transformer frame with a multi-slot gradually varying perimeter according to claim 1, characterized in that, The gradient of the decreasing perimeter inside the slot cavity of the multiple primary side slots (3) is non-uniform, and its decreasing gradient matches the voltage drop gradient on the primary side winding.
4. The transformer frame with a multi-slot gradually varying perimeter according to claim 1, characterized in that, The secondary side groove (4) is located at one end of the winding post (2) near the second pin (6).
5. A transformer frame with a multi-slot gradually varying perimeter according to claim 1, characterized in that, An insulating partition (7) is provided between each pair of adjacent original edge grooves (3) on the skeleton body (1), and the height of the insulating partition (7) is higher than the winding height.
6. A transformer frame with a multi-slot gradually varying perimeter according to claim 5, characterized in that, The insulating partition (7) has an opening (701) for the winding wires between adjacent primary side slots (3) to pass through.
7. A transformer frame with a multi-slot gradually varying perimeter according to claim 6, characterized in that, The edges of the opening (701) are rounded or polished to form a smooth guide surface without stress concentration.
8. A transformer frame with a multi-slot gradually varying perimeter according to claim 1, characterized in that, The skeleton body (1) has a rectangular hole (8) in the middle for inserting the iron core.
9. A transformer frame with a multi-slot gradually varying perimeter according to claim 1, characterized in that, The skeleton body (1) is provided with a first end plate and a second end plate. The first pin (5) is provided on the first end plate and the second pin (6) is provided on the second end plate. The secondary side groove (4) and the original side groove (3) are separated by the second end plate.
10. A transformer frame with a multi-slot gradually varying perimeter according to claim 1, characterized in that, The skeleton body (1) is also provided with two secondary pins for the two ends of the winding of the secondary side slot (4) to be electrically connected.