Heat dissipation insulating transformer

Abstract

The utility model relates to a heat dissipation insulating transformer in the field of transformers, which comprises a base, an iron core, a coil and a top plate, a framework is arranged on the outer side of the iron core, the coil is wound on the surface of the framework, the framework is made of ceramics, an insulating shell is arranged on the base, the insulating shell is sleeved on the outer side of the coil, and a bottom cover and a top cover are respectively arranged at two ends of the insulating shell. The insulating shell is filled with epoxy resin, the two ends of the framework make contact with the bottom cover and the top cover respectively, the side walls of the bottom cover and the top cover are connected with a heat dissipation assembly, the heat dissipation assembly comprises a heat conduction plate, heat dissipation fins and a heat dissipation fan, the two ends of the heat conduction plate are connected with the bottom cover and the top cover respectively, and the heat dissipation fan is installed on the surface of the heat conduction plate through a support. A heat dissipation air channel is formed between the heat dissipation fan and the heat conduction plate, the heat dissipation fins are arranged in the heat dissipation air channel, a high-heat-conduction ceramic framework is adopted, and on the basis that the insulation performance is guaranteed, the ceramic framework rapidly conducts heat generated when the coil runs to the bottom cover and the top cover which are in contact with the two ends.

Description

Technical Field

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

[0002] Small transformers are widely used in electronic equipment, power systems, communication equipment, and industrial control, primarily for voltage conversion, signal isolation, and impedance matching. As electronic equipment evolves towards higher power density and miniaturization, the operating temperature of transformers has become a critical factor affecting their reliability and lifespan. Poor heat dissipation can lead to insulation aging, efficiency degradation, and even equipment damage. Therefore, optimizing heat dissipation structures has become an important research direction in transformer design.

[0003] Currently, common small transformers typically consist of an iron core, coils, a frame, an insulating shell, and a heat dissipation structure. The coils are wound on a plastic or ordinary insulating frame, and the iron core and coils are isolated by insulating material. The shell is generally made of plastic or metal, and some products use potting compound for fixation and insulation. Heat dissipation mainly relies on natural convection or simple metal heat sinks. Some high-power transformers may be equipped with cooling fans, but the heat dissipation path is relatively simple, with heat mainly dissipated through the shell or natural airflow.

[0004] The existing small transformers have poor thermal conductivity in their frame. After sealing, the heat generated by the coil is difficult to conduct to the outer casing quickly. They mainly rely on natural air convection for heat dissipation, resulting in a high temperature rise and affecting long-term stability. Utility Model Content

[0005] In order to overcome the shortcomings of existing technical solutions, this utility model provides a heat dissipation and insulation transformer, which can effectively solve the technical problem of low heat dissipation efficiency after sealing.

[0006] The technical solution adopted by this utility model to solve its technical problem is:

[0007] A heat-dissipating and insulating transformer includes a base, an iron core, a coil, and a top plate. The iron core is mounted on the upper end of the base, the coil is disposed on the outer side of the iron core, and the top plate is mounted on the end of the iron core away from the base. The top plate is mounted on a terminal connector. The coil is electrically connected to the terminal connector via a guide. A frame is disposed on the outer side of the iron core, and the coil is wound around the surface of the frame. The frame is made of ceramic. An insulating shell is disposed on the base and is fitted over the outer side of the coil. A bottom cover and a top cover are respectively disposed at both ends of the insulating shell. The insulating shell is filled with epoxy resin, which impregnates the entire coil. The two ends of the frame are in contact with the bottom cover and the top cover, respectively. A heat dissipation assembly is connected to the side walls of the bottom cover and the top cover. The heat dissipation assembly includes a heat-conducting plate, heat dissipation fins, and a heat dissipation fan. The two ends of the heat-conducting plate are connected to the bottom cover and the top cover, respectively. The heat dissipation fan is mounted on the surface of the heat-conducting plate via a bracket, and a heat dissipation channel is formed between the heat dissipation fan and the heat-conducting plate. The heat dissipation fins are disposed in the heat dissipation channel.

[0008] Furthermore, the surface of the skeleton is provided with spiral reinforcing ribs, the height of the reinforcing ribs is 2-4mm, the spacing between adjacent reinforcing ribs is 5-8mm, and they form an angle of 30-45° with the winding direction of the coil.

[0009] Furthermore, the top of the spiral reinforcing rib is provided with an arc-shaped guide groove with a depth of 0.5-1.2mm.

[0010] Furthermore, the heat dissipation fins are wavy, with a peak height of 8-15mm and a flow guide hole at the trough, with a diameter of 2-5mm.

[0011] Furthermore, the heat-conducting plate is provided with dovetail grooves at both ends, and the side walls of the bottom cover and the top cover are provided with dovetail blocks. The heat-conducting plate, the bottom cover and the top cover are connected by inserting the dovetail blocks into the dovetail grooves.

[0012] Furthermore, the epoxy resin adopts a layered filling structure, with the inner layer being an epoxy resin layer containing alumina filler, the filler content being 40-60wt%, and the outer layer being a pure epoxy resin layer, with a glass fiber mesh provided between the two layers.

[0013] Furthermore, the inner wall of the insulating shell is provided with an annular boss, and the edges of the bottom cover and top cover are provided with stepped grooves that mate with the annular boss.

[0014] Compared with existing technologies, the advantages of this invention are as follows: Using a high thermal conductivity ceramic skeleton as the coil winding substrate ensures insulation performance while rapidly conducting the heat generated during coil operation to the bottom and top covers at both ends, forming an axial heat dissipation main channel. Simultaneously, the epoxy resin filling layer tightly encapsulates the coil, achieving electrical insulation and concentrating the heat collected by the bottom and top covers to the large surface area heat dissipation fins. A cooling fan then forms directional airflow channels between the heat dissipation fin array, improving heat dissipation efficiency compared to traditional natural convection cooling. The ceramic skeleton and epoxy resin layer form a rigid-elastic composite structure. The high thermal stability of the ceramic material and the matching design of the epoxy resin's coefficient of thermal expansion ensure that no structural deformation occurs inside the device during drastic temperature changes. Attached Figure Description

[0015] Figure 1 This is the front view of the present invention;

[0016] Figure 2 This is the left view of the present invention;

[0017] Figure 3 This is a schematic diagram of the structure of the insulating shell, iron core and coil in this utility model;

[0018] Figure 4 This is a schematic diagram of the heat dissipation fins in this utility model;

[0019] The following are the labels in the diagram: 1-base, 2-iron core, 3-coil, 4-top plate, 5-terminal connector, 6-frame, 7-insulating shell, 8-bottom cover, 9-top cover, 10-epoxy resin, 11-heat conduction plate, 12-heat dissipation fins, 13-heat dissipation fan, 14-airflow hole. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0021] The following is combined Figures 1-4 A detailed description of a heat dissipation and insulation transformer according to this utility model is provided:

[0022] A heat-dissipating and insulating transformer includes a base 1, an iron core 2, a coil 3, and a top plate 4. The iron core 2 is mounted on the upper end of the base 1, the coil 3 is disposed on the outer side of the iron core 2, and the top plate 4 is mounted on the end of the iron core 2 away from the base 1. The top plate 4 is mounted on a terminal connector 5, and the coil 3 is electrically connected to the terminal connector 5 via a guide. A frame 6 is provided on the outer side of the iron core 2, and the coil 3 is wound around the surface of the frame 6. The frame 6 is made of ceramic. An insulating shell 7 is provided on the base 1, and the insulating shell 7 is fitted over the outer side of the coil 3. Bottom covers are respectively provided at both ends of the insulating shell 7. 8 and top cover 9, the insulating shell 7 is filled with epoxy resin 10, the epoxy resin 10 is immersed in the middle section of the entire coil 3 and iron core 2, the two ends of the frame 6 are in contact with the bottom cover 8 and top cover 9 respectively, the side walls of the bottom cover 8 and top cover 9 are connected to heat dissipation components, the heat dissipation components include heat conduction plate 11, heat dissipation fins 12 and heat dissipation fan 13, the two ends of heat conduction plate 11 are connected to the bottom cover 8 and top cover 9 respectively, the heat dissipation fan 13 is installed on the surface of heat conduction plate 11 through bracket, heat dissipation air channel is formed between heat dissipation fan 13 and heat conduction plate 11, and heat dissipation fins 12 are set in heat dissipation air channel.

[0023] A high thermal conductivity ceramic skeleton 6 is used as the winding substrate for the coil 3. While ensuring insulation performance, the ceramic skeleton 6 rapidly conducts the heat generated by the coil 3 during operation to the bottom cover 8 and top cover 9 at both ends, forming an axial heat dissipation main channel. At the same time, the epoxy resin 10 filling layer tightly wraps the coil 3, achieving electrical insulation and concentrating the heat collected by the bottom cover 8 and top cover 9 to the large surface area heat dissipation fins 12. The cooling fan 13 forms a directional airflow channel between the fin array, which improves the heat dissipation efficiency compared to traditional natural convection cooling. The ceramic skeleton 6 and the epoxy resin 10 layer form a rigid-elastic composite structure. The high thermal stability of the ceramic material and the thermal expansion coefficient of the epoxy resin 10 are matched to ensure that no structural deformation occurs inside the device under drastic temperature changes.

[0024] The surface of the frame 6 is provided with spiral reinforcing ribs, the height of which is 4mm and the spacing between adjacent reinforcing ribs is 8mm. The reinforcing ribs form a 35° angle with the winding direction of the coil 3, which can enhance the contact area between the coil 3 and the frame 6, improve the heat conduction efficiency, and prevent the coil 3 from loosening or shifting. The top of the spiral reinforcing ribs is provided with an arc-shaped guide groove with a depth of 1.2mm. The arc-shaped guide groove can guide the coil 3 to be evenly arranged, avoid local stress concentration, further optimize the heat dissipation path, and reduce the generation of hot spots.

[0025] The heat dissipation fins 12 are wavy with a peak height of 11mm and a guide hole 14 at the trough with a diameter of 2mm. The wavy design of the heat dissipation fins 12 increases the heat dissipation surface area and optimizes the airflow distribution through the guide hole 14 at the trough, reducing wind resistance and improving the airflow penetration of the cooling fan 13, thereby increasing the heat dissipation efficiency by more than 20%.

[0026] The heat-conducting plate 11 has dovetail grooves at both ends, and the side walls of the bottom cover 8 and the top cover 9 are provided with dovetail blocks. The heat-conducting plate 11, the bottom cover 8 and the top cover 9 are connected by inserting the dovetail blocks into the dovetail grooves to ensure mechanical stability and reduce contact thermal resistance. This allows heat to be transferred more efficiently from the outer shell to the heat dissipation fins 12, and avoids a decrease in heat dissipation performance due to loose connections.

[0027] The epoxy resin 10 adopts a layered filling structure. The inner layer is an epoxy resin 10 layer containing alumina filler with a filler content of 40-60wt%. The outer layer is a pure epoxy resin 10 layer. A glass fiber mesh is provided between the two layers. The alumina filler in the inner layer improves thermal conductivity and accelerates the conduction of internal heat to the outside. The pure epoxy resin 10 in the outer layer ensures insulation strength. The glass fiber mesh enhances the interlayer bonding force, prevents delamination and cracking caused by thermal expansion and contraction, and ensures long-term reliability.

[0028] The inner wall of the insulating shell 7 is provided with an annular boss, and the edges of the bottom cover 8 and the top cover 9 are provided with stepped grooves that cooperate with the annular boss. The annular boss on the inner wall of the insulating shell 7 and the stepped grooves of the bottom cover 8 and the top cover 9 are tightly fitted to improve the sealing performance, prevent the epoxy resin 10 from leaking, and enhance the overall structure's vibration resistance, making it suitable for high mechanical stress environments.

[0029] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A heat dissipating insulated transformer comprising a base, a core, a coil and a top plate, the core being mounted on the upper end of the base, the coil being arranged on the outer side of the core, and the top plate being mounted on the end of the core away from the base, characterized in that: The top plate is installed on a terminal connector, the coil is electrically connected with the terminal connector through a guide, the outer side of the iron core is provided with a framework, the coil is wound on the surface of the framework, the framework is made of ceramic, the base is provided with an insulating shell, the insulating shell is sleeved on the outer side of the coil, the two ends of the insulating shell are respectively provided with a bottom cover and a top cover, the insulating shell is filled with epoxy resin, the epoxy resin immerses the whole coil, the two ends of the framework are respectively in contact with the bottom cover and the top cover, the side walls of the bottom cover and the top cover are connected with a heat dissipation assembly, the heat dissipation assembly comprises a heat conduction plate, heat dissipation fins and a heat dissipation fan, the two ends of the heat conduction plate are connected with the bottom cover and the top cover respectively, the heat dissipation fan is installed on the surface of the heat conduction plate through a support, and a heat dissipation air duct is formed between the heat dissipation fan and the heat conduction plate.

2. A thermally insulated transformer according to claim 1, characterized in that: The framework surface is provided with spiral reinforcing ribs, the reinforcing rib height is 2-4mm, the adjacent reinforcing rib spacing is 5-8mm, and a 30-45° angle is formed with the winding direction of the coil.

3. A thermally insulated transformer according to claim 2, characterized in that: The top of the spiral reinforcing rib is provided with a circular arc guide groove, and the guide groove depth is 0.5-1.2mm.

4. A thermally insulated transformer according to any one of claims 1-3, characterized in that: The heat dissipation fins are in a wave shape, the wave peak height is 8-15mm, the wave trough is provided with a flow guide hole, and the flow guide hole diameter is 2-5mm.

5. A thermally insulated transformer according to any one of claims 1-3, characterized in that: The two ends of the heat conduction plate are provided with dovetail grooves, the side walls of the bottom cover and the top cover are provided with dovetail blocks, and the heat conduction plate, the bottom cover and the top cover are connected by inserting the dovetail blocks into the dovetail grooves.

6. A thermally insulated transformer according to any one of claims 1-3, characterized in that: The epoxy resin adopts a layered filling structure, the inner layer is an epoxy resin layer containing aluminum oxide fillers, the filler content is 40-60wt%, the outer layer is a pure epoxy resin layer, and a glass fiber mesh is arranged between the two layers.

7. A thermally insulated transformer according to any one of claims 1-3, characterized in that: The inner wall of the insulating shell is provided with an annular boss, and the edges of the bottom cover and the top cover are provided with stepped grooves matched with the annular boss.

Images