Novel double-framework transformer structure

Abstract

The utility model discloses a novel double-framework transformer structure, which comprises a shell and two groups of transformation modules arranged in the shell, and the shell is filled with heat dissipation type pouring sealant for pouring gaps of the transformation modules. Each group of transformation module comprises a primary coil winding, a secondary coil winding, a winding double skeleton and an E-shaped magnetic core, the winding double skeleton comprises a hollow tubular inner skeleton and an outer skeleton with through holes at two ends, the primary coil winding is wound on the outer wall of the inner skeleton, and the secondary coil winding is wound on the outer wall of the outer skeleton. The two E-shaped magnetic cores are oppositely buckled to the upper ends and the lower ends of the inner framework and the outer framework, middle columns of the two E-shaped magnetic cores are inserted into through holes in the upper end and the lower end of the inner framework respectively, and the outer side protruding walls of the two E-shaped magnetic cores are in butt joint. The winding double frameworks formed by sleeving the inner framework and the outer framework inside and outside serve as coil supporting frameworks of the primary winding and the secondary winding, the gap between the inner framework and the outer framework serves as a heat dissipation channel, and heat generated when the transformer works is dissipated by filling the heat dissipation type pouring sealant for pouring.

Description

TECHNICAL FIELD

[0001] The utility model relates to magnetic component technology field especially relates to a novel double skeleton transformer structure. BACKGROUND

[0002] The transformer usually includes metal shell, winding, skeleton, terminal, the current transformer usually is fixed with the skeleton in the metal shell inside, the winding is arranged on the skeleton, the metal shell only plays the protection winding and internal electronic component. The transformer plays the vital role in power electronics, communication, new energy field, realizes the transformation and transmission in the power electronics field, provides stable magnetic circuit for high frequency power amplifier and other equipment in the communication field, in the new energy field, such as solar inverter, electric automobile charging pile, etc. High power magnetic core component is indispensable key component. With the rapid development of science and technology, the requirement of this kind of magnetic component such as transformer is higher and higher, therefore need to design the transformer of multiple winding, to realize the transformation of multiple voltage, to improve the overall efficiency. In the design of the transformer of multiple winding, while achieving the above-mentioned purpose, the overall structure of the designed transformer needs to be considered small, and the problem of large power transformer heat needs to be solved. SUMMARY

[0003] Therefore, the utility model provides a novel double skeleton transformer structure, realizes the small volume of the whole transformer, and can solve the heat dissipation problem of the transformer.

[0004] The utility model discloses a novel double skeleton transformer structure, including the shell and install two groups of voltage transformation module in the shell, and the shell is filled with heat dissipation type filling sealant and fills the seal gap between voltage transformation module. Each group of voltage transformation module includes primary coil winding, secondary coil winding, winding double skeleton and E type magnetic core, the winding double skeleton includes the tubular inner skeleton and outer skeleton that two ends through -hole are hollow, the inner skeleton outer wall is set in the whole in the outer skeleton after winding primary coil winding, and the outer wall of outer skeleton winds secondary coil winding. E type magnetic core includes two, and two E type magnetic cores are opposite and are buckled on the upper and lower ends of inner skeleton and outer skeleton, and the middle column of two E type magnetic cores is inserted in the upper and lower end through -hole of inner skeleton, and the lateral convex wall of two E type magnetic cores is opposite.

[0005] Further, the inner skeleton and the outer skeleton are circular tubes, and the outer walls of the inner skeleton and the outer skeleton are provided with a plurality of evenly distributed gap positions, the side walls of the inner skeleton are uniformly provided with convex ribs for abutting against the inner walls of the outer skeleton along the vertical direction, so that there is a gap between the outer wall of the inner skeleton and the inner wall of the outer skeleton.

[0006] Further, the upper and lower ends of the inner skeleton and the outer skeleton are provided with outwardly turned convex edge portions for winding limiting.

[0007] Furthermore, the inner and outer skeletons are provided with protruding strips on both sides of the outwardly convex edges at the upper and lower ends, and the protruding strips form a snap-fit ​​position for assembling the E-type magnetic core.

[0008] Furthermore, both the inner and outer skeletons are injection molded from plastic material.

[0009] Furthermore, the outer shell is a metal shell with through holes at the top and bottom formed by side walls. A base is provided at the bottom of the metal shell to support the bottom of the transformer module. The base is an "I"-shaped plate with wire grooves and electrical terminals on the upper and lower sides. The recesses on the left and right sides of the base are for accommodating one set of the transformer module. The leads of the primary coil winding and the secondary coil winding are embedded in the wire grooves and welded to the electrical terminals.

[0010] Furthermore, the inner side of the recess of the base is provided with an insertion groove for inserting the lower edge of the outer shell. The inner wall of the insertion groove is provided with a snap-fit ​​protrusion, and the lower side wall of the outer shell is provided with a snap-fit ​​opening that snaps into the snap-fit ​​protrusion.

[0011] Furthermore, insulating paper is pasted on the upper surface and sides of the two E-type magnetic cores of the transformer module that are interlocked.

[0012] The dual-frame transformer structure designed using this technical solution has the following beneficial effects:

[0013] 1. By designing a transformer with two sets of transformer modules, multiple voltage conversions can be provided, improving overall efficiency and meeting the needs of different application scenarios. Simultaneously, a double-framed winding system with inner and outer frames nested together serves as the coil winding support framework for the primary and secondary windings. The gap between the inner and outer frames acts as a heat dissipation channel, and the filling with heat-dissipating potting compound helps dissipate the heat generated during transformer operation. Good heat dissipation performance reduces the transformer's temperature rise, improving its operating efficiency and reliability. For high-power transformers, heat dissipation is particularly critical; the double-framed structure effectively improves heat dissipation, ensuring stable operation of the transformer under high load conditions.

[0014] 2. The adoption of a double-frame winding structure creates a natural insulating layer between the inner and outer frames. This significantly increases the creepage distance and clearance between different windings, effectively reducing the risk of transformer failure due to short circuits between windings. For high-voltage applications or those with stringent insulation requirements, the double-frame design provides more reliable insulation protection, ensuring the transformer operates safely and stably in complex electrical environments. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the overall structure of the transformer of this utility model.

[0016] Figure 2 The exploded schematic view of the transformer structure of the utility model.

[0017] Figure 3 The further exploded schematic view of the transformer structure of the utility model.

[0018] Figure 4 The exploded schematic view of the transformer module structure of the utility model.

[0019] Figure 5 The schematic view of the base structure of the utility model.

[0020] Reference signs:

[0021] 10, transformer module; 101, inner skeleton; 1011, convex rib; 1013, convex strip part; 102, primary coil winding; 103, outer skeleton; 104, secondary coil winding; 105, E-shaped magnetic core; 106, insulating paper; 20, shell; 201, bayonet; 30, heat dissipation type pouring sealant; 40, base; 401, wire passing groove; 402, plug-in slot; 403, clamping protrusion; 50, power terminal. DETAILED DESCRIPTION

[0022] The technical solutions in the embodiments of the present disclosure will be clearly and completely described below with reference to the drawings, obviously, the described embodiments are only part of the embodiments of the present disclosure, not all the embodiments. Based on the embodiments of the present disclosure, all other embodiments obtained by those skilled in the art without creative labor also belong to the protection scope of the present disclosure.

[0023] Please refer to Figures 1 to 5 A novel double-skeleton transformer structure is provided for the technical solution, which comprises a shell 20 and two groups of transformer modules 10 installed in the shell 20, and the shell 20 is filled with heat dissipation type pouring sealant 30 to seal the gaps between the transformer modules 10; each group of transformer modules 10 comprises a primary coil winding 102, a secondary coil winding 104, a wire winding double skeleton and an E-shaped magnetic core, the wire winding double skeleton comprises a tubular inner skeleton 101 with a hollow and through holes at both ends and an outer skeleton 103, the primary coil winding 102 is wound on the outer wall of the inner skeleton 101 and the whole is sleeved on the outer skeleton 103, and the secondary coil winding 104 is wound on the outer wall of the outer skeleton 103; the E-shaped magnetic core 105 comprises two, two E-shaped magnetic cores 105 are oppositely buckled on the upper and lower ends of the inner skeleton 101 and the outer skeleton 103, the middle columns of the two E-shaped magnetic cores 105 are respectively plugged into the upper and lower end through holes of the inner skeleton 101, and the outer side convex walls of the two E-shaped magnetic cores 105 are connected.

[0024] The inner skeleton 101 and the outer skeleton 103 are sleeved to form a winding double skeleton as a coil winding support skeleton of the primary winding and the secondary winding. The gap between the inner skeleton 101 and the outer skeleton 103 can be used as a heat dissipation channel, and the heat dissipation type filling glue 30 is filled to help dissipate the heat generated during the operation of the transformer. The good heat dissipation performance can reduce the temperature rise of the transformer, and improve the working efficiency and reliability.

[0025] Please refer to Figures 2 to 4 , preferably, the inner skeleton 101 and the outer skeleton 103 are circular tubes, and the outer walls of the inner skeleton 101 and the outer skeleton 103 are provided with a plurality of evenly distributed gap positions. The side walls of the inner skeleton 101 are uniformly provided with a protruding rib 1011 on both sides in the vertical direction for abutting the inner wall of the outer skeleton 103, so that there is a gap between the outer wall of the inner skeleton 101 and the inner wall of the outer skeleton 103. After the inner skeleton 101 is assembled into the outer skeleton 103 after winding the primary coil winding 102, the inner skeleton 101 winding the primary coil winding 102 is not easy to shift and shake, and the peripheral gap space is uniform, which is convenient for the filling of the heat dissipation type filling glue 30, and the glue can be filled more uniformly to achieve uniform heat dissipation.

[0026] Please refer to the drawings Figure 2 、 Figure 4 , further, the upper and lower ends of the inner skeleton 101 and the outer skeleton 103 are provided with outwardly turned protruding edge portions for winding limiting. The opposite sides of the outwardly turned protruding edge portions of the upper and lower ends of the inner skeleton 101 and the outer skeleton 103 are respectively provided with protruding strip portions 1013, and the protruding strip portions 1013 form clamping positions for assembling the E-type magnetic core 105, so that the E-type magnetic core 105 can be quickly assembled on the winding double skeleton.

[0027] Preferably, the inner skeleton 101 and the outer skeleton 103 are both made of plastic material and are injection molded.

[0028] Preferably, the upper surfaces and side surfaces of the two E-type magnetic cores 105 of the transformer module 10 are pasted with insulating paper 106.

[0029] Please refer to Figure 3 、 Figure 5Preferably, the outer shell 20 is a metal shell with through holes at the top and bottom formed by side walls. A base 40 is provided at the bottom of the metal shell to support the bottom of the transformer module 10. The base 40 is an "I"-shaped plate with wire grooves 401 and electrical terminals 50 on the upper and lower sides. The recesses on the left and right sides of the base 40 are for accommodating one set of the transformer module 10. The leads of the primary coil winding 102 and the secondary coil winding 104 are embedded in the wire grooves 401 and welded to the electrical terminals 50. The inner side of the recesses of the base 40 is provided with insertion slots 402 for inserting the lower edge of the outer shell 20. The inner wall of the insertion slots 402 is provided with snap-fit ​​protrusions 403, and the corresponding lower side wall of the outer shell 20 is provided with snap-fit ​​openings 201 that snap with the snap-fit ​​protrusions 403.

[0030] The various embodiments of this disclosure have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen to best explain the principles, practical application, or improvement of the technology in the market, or to enable others skilled in the art to understand the embodiments disclosed herein.

Claims

1. A novel dual skeleton transformer structure, characterized by, The system includes a housing and two sets of transformer modules installed within the housing. The housing is filled with heat-dissipating potting compound to seal the gaps between the transformer modules. Each transformer module includes a primary coil winding, a secondary coil winding, a double-wound frame, and E-shaped magnetic cores. The double-wound frame includes a hollow tubular inner frame and an outer frame with through holes at both ends. The primary coil winding is wound on the outer wall of the inner frame and then fitted entirely into the outer frame. The secondary coil winding is wound on the outer wall of the outer frame. The system includes two E-shaped magnetic cores, which are fastened to the upper and lower ends of the inner and outer frames respectively. The central posts of the two E-shaped magnetic cores are respectively inserted into the through holes at the upper and lower ends of the inner frame, and the outer convex walls of the two E-shaped magnetic cores are connected to each other.

2. The novel dual skeleton transformer structure according to claim 1, characterized in that, The inner and outer skeletons are circular tubes, and the outer walls of the inner and outer skeletons are provided with multiple evenly distributed perforations. The side walls of the inner skeleton are provided with protruding ribs on both sides along the vertical direction to abut against the inner wall of the outer skeleton, so that there is a gap between the outer wall of the inner skeleton and the inner wall of the outer skeleton.

3. The novel dual skeleton transformer structure according to claim 2, characterized in that, Both the inner and outer skeletons are provided with outwardly convex edges at their upper and lower ends for winding and limiting.

4. The novel dual skeleton transformer structure according to claim 3, characterized in that, The inner and outer skeletons have protruding strips on opposite sides of the outwardly convex edges at the upper and lower ends, which together form a snap-fit ​​position for assembling the E-type magnetic core.

5. The novel dual skeleton transformer structure according to claim 4, wherein, Both the inner and outer skeletons are injection molded from plastic material.

6. The novel dual skeleton transformer structure according to claim 1, wherein, The outer shell is a metal shell with through holes at the top and bottom formed by side walls. A base is provided at the bottom of the metal shell to support the bottom of the transformer module. The base is an "I"-shaped plate with wire grooves and electrical terminals on the upper and lower sides. The recesses on the left and right sides of the base are for accommodating one set of the transformer module. The leads of the primary coil winding and the secondary coil winding are embedded in the wire grooves and welded to the electrical terminals.

7. The novel dual skeleton transformer structure according to claim 6, characterized in that, The base has an insertion slot on the inner side of the recess for inserting the lower edge of the outer shell. The inner wall of the insertion slot has a snap-fit ​​protrusion, and the lower side wall of the outer shell has a snap-fit ​​opening that engages with the snap-fit ​​protrusion.

8. The novel dual skeleton transformer structure according to any one of claims 1-7, characterized in that, Insulating paper is pasted on the upper surface and sides of the two E-type magnetic cores of the transformer module that are interlocked.

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