5kW low-temperature-rise planar transformer
By designing a 5kW low-temperature rise planar transformer, the problems of high temperature rise and low efficiency caused by traditional winding structures were solved, achieving better heat dissipation and production efficiency, and reducing labor costs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- ZIXING HUIHUA ELECTRONICS CO LTD
- Filing Date
- 2025-05-08
- Publication Date
- 2026-05-05
AI Technical Summary
Existing high-power power transformers suffer from high temperature rise due to traditional winding structures, which affects their service life and results in low production efficiency, making automated production impossible and labor costs high.
The design employs a 5kW low-temperature rise planar transformer, which includes a magnetic core, output components, coils, and a PCB. The coils are exposed and in contact with the air. The PCBs and coils are stacked alternately four times. Flat copper leads are used as the output terminals. The air gap of the magnetic core is placed on the open-loop side, combined with air duct heat dissipation, resulting in a robust overall structure.
It achieves better heat dissipation and eddy current temperature rise release, reduces product temperature by 10-20℃, increases production efficiency by 50%, reduces labor costs by 70%, and improves product consistency.
Smart Images
Figure CN224203918U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the technical field of transformers, specifically a 5kW low-temperature rise planar transformer. Background Technology
[0002] Currently, most high-power power transformers on the market use traditional winding methods. Due to the tight winding of traditional winding, coupled with the wrapping of the frame, retaining walls, tape, etc., the temperature rise generated during transformer operation cannot be dissipated well, reaching a high temperature of 130-140 degrees Celsius, which will affect the service life of the product. In addition, high-power winding structure products can only be made manually and cannot achieve automated production, resulting in low production efficiency and high labor costs.
[0003] Therefore, in view of the above situation, there is an urgent need to provide a 5kW low-temperature rise planar transformer to overcome the shortcomings in current practical applications. Utility Model Content
[0004] The purpose of this invention is to provide a 5kW low-temperature rise planar transformer, which aims to solve the problems mentioned in the background art.
[0005] This invention is implemented as follows: a 5kW low-temperature planar transformer includes a magnetic core, an output component, a coil and a PCB located inside the magnetic core, the coil being exposed and in direct contact with the air, and the PCB and the output component being connected.
[0006] As a further embodiment of this utility model: the PCB and coil are alternately stacked four times to form a composite structure, and the alternating four-times combination strengthens the coupling between the primary and secondary windings and improves product efficiency.
[0007] As a further aspect of this utility model: the output component is a flat copper foot. The flat copper foot, as the output end, is conducive to heat dissipation, and the overall temperature of the product is 10-20℃ lower than that of the traditional winding structure.
[0008] As a further embodiment of this invention, the flat copper feet are connected to the PCB by welding.
[0009] As a further embodiment of this utility model: the magnetic core adopts an EI type structure, and the air gap is installed on the open-loop side. The eddy current temperature rise generated by the air gap of the magnetic core being placed on the open-loop side can be effectively carried away by the air duct.
[0010] As a further embodiment of this utility model: the magnetic core is externally mounted with a base that is integrated with the output component, and the base and the output component are integrated to achieve a solid overall structure.
[0011] Compared with the prior art, the beneficial effects of this utility model are as follows:
[0012] 1. Good heat dissipation: The combination of PCB and coil, external base, and exposed coil in direct contact with air facilitate heat dissipation.
[0013] 2. Eddy current temperature rise is easily released: The eddy current temperature rise generated by placing the air gap of the magnetic core on the open-loop side can be effectively carried away through the air duct.
[0014] 3. Low temperature: A flat copper foot is also designed as the output end, which is conducive to heat dissipation. The overall temperature of the product is 10-20℃ lower than that of the traditional winding structure.
[0015] 4. Good product consistency: The materials used are simple and the assembly is convenient, which can greatly reduce the large fluctuations in product performance caused by inconsistencies in materials and manual operation.
[0016] 5. Low cost: The product is easy to automate, increasing production efficiency by 50% compared to traditional methods, and reducing labor costs by 70%. Attached Figure Description
[0017] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.
[0018] Figure 1 This is a schematic diagram of the main structure of this utility model.
[0019] In the attached diagram: 1-Magnetic core, 2-Coil, 3-Base, 4-PCB, 5-Output component. Detailed Implementation
[0020] The technical solution of this utility model will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.
[0021] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and 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, and therefore should not be construed as a limitation of this utility model. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.
[0022] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this utility model according to the specific circumstances.
[0023] The present invention will be further explained below with reference to specific embodiments.
[0024] Please see Figure 1 This utility model provides a 5kW low-temperature rise planar transformer, which includes a magnetic core 1, an output component 5, a coil 2 and a PCB 4 located inside the magnetic core 1. The coil 2 is exposed and in direct contact with the air, and the PCB 4 and the output component 5 are connected.
[0025] In the embodiments of this utility model, the PCB4 is combined with the coil 2 and the base 3 is external. The exposed coil is in direct contact with the air, which facilitates heat dissipation and effectively improves the heat dissipation performance of the 5kW low temperature rise planar transformer. The materials used are simple and easy to assemble. It can greatly reduce the large fluctuations in product performance caused by inconsistencies in materials and manual operation. The product is easy to automate production, and the production efficiency is 50% higher than that of the traditional method. The labor cost can be reduced by 70%.
[0026] In one embodiment of this utility model, please refer to Figure 1 The PCB4 and coil 2 are alternately stacked four times to form a composite structure;
[0027] The coil 2 and PCB4 are combined in four alternating cycles to strengthen the coupling between the primary and secondary windings and improve product efficiency.
[0028] The output component 5 has flat copper leads, which are soldered to PCB4 to achieve high current output. The flat copper leads, as the output end, are conducive to heat dissipation, and the overall temperature of the product is 10-20℃ lower than that of the traditional winding structure.
[0029] The magnetic core 1 adopts an EI type structure, and the air gap is installed on the open-loop side. The eddy current temperature rise generated by the air gap of the magnetic core being placed on the open-loop side can be effectively carried away by the air duct.
[0030] In one embodiment of this utility model, please refer to Figure 1 The magnetic core 1 is externally mounted with a base 3 that is integrated with the output component 5. The base 3 and the output component 5 are integrated to achieve a solid overall structure.
[0031] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.
Claims
1. A 5kW low-temperature planar transformer, comprising a magnetic core (1), an output component (5), and a coil (2) and a PCB (4) located within the magnetic core (1), characterized in that, The coil (2) is exposed and in direct contact with the air, and the PCB (4) and the output component (5) are connected.
2. The 5kW low-temperature rise planar transformer according to claim 1, characterized in that, The PCB (4) and coil (2) are stacked alternately four times to form a composite structure.
3. The 5kW low-temperature rise planar transformer according to claim 1, characterized in that, The output component (5) has flat copper feet.
4. The 5kW low-temperature rise planar transformer according to claim 3, characterized in that, The flat copper feet are connected to the PCB (4) by soldering.
5. The 5kW low-temperature rise planar transformer according to claim 1, characterized in that, The magnetic core (1) adopts an EI type structure, and the air gap is installed on the open-loop side.
6. The 5kW low-temperature rise planar transformer according to claim 1, characterized in that, The magnetic core (1) is externally mounted with a base (3) that is integrated with the output component (5).