A drive shielded transformer and voltage converter

Abstract

This utility model discloses a drive-shielded transformer and voltage converter, belonging to the field of transformer technology. The drive-shielded transformer includes a frame, a primary winding, a secondary winding, and a magnetic core. The primary and secondary windings are sequentially wound around the frame, and a shielding layer is provided between the primary and secondary windings. The magnetic core is located at both ends of the frame. The leads of the primary winding, secondary winding, and shielding layer are connected to the pins of the frame, and the shielding layer is grounded through the pins. This drive-shielded transformer uses copper foil shielding and grounding to shield the parasitic capacitance, leakage inductance, and interference generated by the primary and secondary windings, and releases them through the grounding leads. This significantly reduces the leakage inductance and parasitic capacitance of the transformer, giving the transformer the best electromagnetic compatibility effect during operation, isolating noise and spurious waves within the operating frequency, resulting in higher power conversion efficiency and lower temperature rise during continuous operation. This transformer features small size, wide operating frequency range, and good structural assembly.

Description

Technical Field

[0001] This utility model relates to the field of transformer technology, specifically to a drive shielded transformer and voltage converter. Background Technology

[0002] With the rapid rise of industries such as new energy vehicles and industrial robots, as well as the rapid development of surface mount technology and integrated circuits, the requirements for components in terms of electromagnetic compatibility, power conversion, temperature rise control, and reliability are becoming increasingly stringent. The drive transformer, as a core component in the power drive module, plays a crucial role in energy conversion, voltage regulation, and insulation isolation.

[0003] However, existing transformers have a relatively simple structure, consisting only of a primary winding, a secondary winding, and a magnetic core. The design of this drive transformer primarily focuses on static test parameters, neglecting the impact of circuit topology on performance. This design approach results in poor electromagnetic compatibility and low power conversion efficiency for the drive shielded transformer in practical operation. Furthermore,

[0004] When such transformers operate in power drive modules, they exhibit problems such as poor electromagnetic compatibility, high noise levels, low power conversion efficiency, excessive temperature rise, and insufficient insulation performance. These problems can not only cause the transformer itself to break down and burn out, but may also affect the entire power drive module, leading to serious consequences. Therefore, existing transformers have poor reliability and relatively short service life, making it difficult to meet the high standards required for military-grade and automotive-grade applications. Utility Model Content

[0005] In view of the problems existing in the prior art, this utility model provides a drive shielded transformer and voltage converter that works in a high-voltage environment and has excellent insulation and reliability.

[0006] This utility model is achieved through the following technical solution:

[0007] In a first aspect, this application provides a drive shielded transformer, including a frame, a primary winding, a secondary winding, and a magnetic core;

[0008] The primary winding and secondary winding are sequentially wrapped around the frame, and a shielding layer is provided between the primary winding and the secondary winding. The magnetic core is located at both ends of the frame. The leads of the primary winding, secondary winding and shielding layer are connected to the pins of the frame, and the shielding layer is grounded through the pins.

[0009] As the preferred embodiment of this application, multiple shielding layers are provided between the primary winding and the secondary winding, and an insulating layer is provided between adjacent shielding layers.

[0010] As the preferred embodiment of this application, the shielding layer includes a primary side shielding layer and a secondary side shielding layer;

[0011] The primary-side shielding layer is wrapped around the surface of the primary-side winding, and an insulating layer is provided between the primary-side shielding layer and the primary-side winding.

[0012] The secondary shielding layer is wrapped around the surface of the primary shielding layer, the secondary winding is wound on the outer surface of the secondary shielding layer, and an insulating layer is provided between the primary shielding layer and the secondary shielding layer, and an insulating layer is provided between the secondary shielding layer and the secondary winding.

[0013] As the preferred embodiment of this application, the surface of the secondary winding is provided with a shielding layer.

[0014] As the preferred embodiment of this application, an insulating layer is provided on the lead-out line.

[0015] As the preferred embodiment of this application, the insulation layer of the lead wire is an insulating sleeve fitted onto the lead wire.

[0016] As the preferred embodiment of this application, the skeleton is covered with a shielding shell.

[0017] As the preferred embodiment of this application, the shielding shell is a steel-clad clip, which is placed over the frame.

[0018] As the preferred embodiment of this application, the shielding layer is copper foil.

[0019] Secondly, this application provides a voltage converter, including the aforementioned drive shielded transformer.

[0020] Compared with the prior art, the present invention has the following beneficial technical effects:

[0021] The shielded drive transformer of this application adds a shielding layer between the primary and secondary windings and grounds it. The shielding layer shields the parasitic capacitance and leakage inductance between the primary and secondary windings of the transformer. The parasitic parameters generated during transformer operation are released through the grounding wire. This greatly improves the electrical performance of the transformer, enhances its electromagnetic compatibility, shields distributed capacitance and leakage inductance, increases power conversion efficiency, reduces temperature rise, reduces noise, and increases stability and reliability.

[0022] Furthermore, the transformer is wrapped with nickel-plated steel cladding to shield it from electromagnetic interference between the transformer and other components in the same power drive module, thereby optimizing the transformer's working efficiency. This method is simple to manufacture and significantly reduces the size of the transformer for the same power rating.

[0023] Furthermore, the incoming and outgoing lines of the primary and secondary windings, as well as the grounding wires of the shielding layer, are all led out using bushings, which increases the creepage distance between the pins, enhances the insulation of the transformer, and prevents the primary and secondary windings from breaking down or burning due to being too close together.

[0024] Furthermore, the transformer core utilizes manganese-zinc power ferrite low-power material, which increases the core's saturation current and effectively increases the core's stored energy, resulting in a stable, high-inductance, and compact transformer. Under the influence of large pulse currents in the power drive module circuit, the inductance value does not decay, ensuring its stability. Attached Figure Description

[0025] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a schematic diagram of the structure of the drive shielding transformer of this utility model.

[0027] Figure 2 This is a schematic diagram of the structure of the new winding of this utility model.

[0028] Figure 3 for Figure 2 A sectional view of AA.

[0029] Figure 4 This is a schematic diagram of the welding of the shielding copper foil and the grounding wire of this utility model.

[0030] Figure 5 This is a schematic diagram of the magnetic core of this utility model.

[0031] Figure 6 This is a schematic diagram of the skeleton of this utility model.

[0032] Figure 7 This is a schematic diagram of the steel ladle card of this utility model.

[0033] Figure 8 This is a performance test comparison chart of the drive shielding transformer of this utility model.

[0034] In the diagram: 1-frame; 2-primary winding; 3-secondary winding; 4-primary shielding layer; 5-secondary shielding layer; 6-grounding lead; 7-sleeve; 8-magnetic core; 9-steel lamination clamp. Detailed Implementation

[0035] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0036] Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0037] See Figure 1-7 A drive shielded transformer includes a frame 1, a primary winding 2, a secondary winding 3, and a magnetic core 8.

[0038] The primary winding 2 and the secondary winding 3 are sequentially wrapped around the frame 1, and a shielding layer is provided between the primary winding 2 and the secondary winding 3. The magnetic core 8 is located at both ends of the frame. The leads of the primary winding 2, the secondary winding 3 and the shielding layer are connected to the pins on the frame 1, and the shielding layer is grounded through the pins.

[0039] The shielded transformer has a shielding layer wrapped between the primary winding 2 and the secondary winding 3. The shielding layer is grounded through a pin. The shielding layer shields the parasitic capacitance, leakage inductance and interference generated by the primary and secondary windings and releases them through the grounding lead. This significantly reduces the leakage inductance and parasitic capacitance of the transformer, giving the transformer the best electromagnetic compatibility effect during operation. It isolates noise and spurs within the operating frequency, resulting in higher power conversion efficiency and lower temperature rise during continuous operation.

[0040] In some embodiments, the shielding layer consists of two layers, including a primary shielding layer 4 and a secondary shielding layer 5. The primary shielding layer 4 is wrapped around the surface of the primary winding 2, and an insulating layer is provided between the primary shielding layer 4 and the primary winding 2. The primary shielding layer 4 and the secondary shielding layer 5 are respectively connected to the pins of the bobbin through lead wires.

[0041] The secondary shielding layer 5 is wrapped around the surface of the primary shielding layer 4, the secondary winding 3 is wound on the outer surface of the secondary shielding layer 5, and an insulating layer is provided between the primary shielding layer 4 and the secondary shielding layer 5, and an insulating layer is provided between the secondary shielding layer 5 and the secondary winding 3.

[0042] A primary shielding layer 4 and a secondary shielding layer 5 are arranged from the inside to the outside between the primary winding 2 and the secondary winding 3, and are isolated by an insulating layer. The primary shielding layer 4 shields the parasitic capacitance, leakage inductance and interference generated by the primary winding 2, and releases them through the grounding lead. The secondary shielding layer 5 shields the parasitic capacitance, leakage inductance and interference generated by the primary winding and the secondary winding, and releases them through the grounding lead, so as to avoid the generation of parasitic parameters by electromagnetic coupling between the primary winding 2 and the secondary winding 3 and improve the isolation effect of the drive shielding transformer.

[0043] In some embodiments, the shielding layer is multi-layered, with the multi-layered shielding layers sequentially wrapped between the primary winding 2 and the secondary winding 3, and an insulating layer is provided between two adjacent shielding layers.

[0044] In some embodiments, the shielding layer is copper foil, the insulating layer is polyester tape, and the magnetic core is manganese-zinc power ferrite.

[0045] In some embodiments, both the primary winding 2 and the secondary winding 3 include two leads, which are respectively connected to two pins. The two leads are the input line and the output line, respectively. The shielding layer is connected to the pin through a lead, and the pin is grounded.

[0046] In some embodiments, a sleeve 7 is fitted onto the lead-out line.

[0047] The transformer winding input and output lines and the shielding layer grounding wire are all protected by insulating sleeves, which effectively prevents the risk of arc breakdown caused by bare enameled wires and air or other devices, and protects the safety of the transformer and the entire power drive module.

[0048] In some embodiments, a shielding shell is provided on the frame, which greatly reduces electromagnetic interference between the driven shielded transformer and other devices when the transformer is in operation. To further reduce interference from other devices, an insulating layer and a shielding layer are wound sequentially on the surface of the secondary winding.

[0049] The shielding shell is a steel-clad card 9, which is installed on the frame. The steel-clad card 9 has downward-extending fixing plates at both ends, which are engaged with the end face of the magnetic core. The steel-clad card 9 is made of nickel-plated steel.

[0050] Example 1

[0051] A drive shielded transformer includes a frame 1. First, a primary winding 2 is wound on the frame 1, and then wrapped with polyester tape for 2 turns. Next, a primary copper foil shielding layer 4 is wound on the frame 1, and then wrapped with polyester tape for 2 turns. Then, a secondary copper foil shielding layer 5 is wound on the frame 1, and then wrapped with polyester tape for 2 turns. Next, a secondary winding 3 is wound on the frame 1, and then wrapped with polyester tape for 3 turns.

[0052] The primary and secondary winding input and output lines and the grounding lead 6 of the shielding layer are all wrapped and protected with 10mm sleeves 7, and are respectively wound around pins "1, 2, 4" and "5, 7, 8" of the frame. The excess wire length is cut off, and the wires are soldered in a soldering pot with flux. After the soldering is completed, the magnetic core 8 passes through the frame mounting hole and is fixed with steel ladle clips 9. The transformer is then treated with glue and impregnated with varnish for insulation.

[0053] The frame 1 is made of bakelite, which is heat resistant, has patch-type pins, and is small in size.

[0054] The enameled wire 4 of the primary and secondary windings is made of copper and can withstand temperatures above 180℃.

[0055] Copper foil 2 is made of high-voltage resistant pure copper, with a voltage resistance of over 3000V.

[0056] The magnetic core 7 is a manganese-zinc power ferrite with low loss and good temperature characteristics.

[0057] The steel-clad card is made of nickel-plated steel, providing the best shielding effect.

[0058] See Figure 7 Using existing unshielded transformers (yellow curve), the drive shielded transformer of Embodiment 1 of this application (purple curve), and the drive shielded transformer with ungrounded shielding layer (blue curve), the inductance, leakage inductance, parasitic capacitance, insertion loss, and insulation withstand voltage of the transformers were tested.

[0059] The curves clearly show that our self-developed transformer's insertion loss performance, or electromagnetic compatibility, is significantly superior to conventional transformers across the entire operating frequency range. We compared shielded ungrounded transformers with shielded grounded transformers; the former only shields some parasitic parameters, while the latter effectively shields all parasitic parameters by releasing them through the shielded grounding wire. This reduces key electrical performance parameters such as leakage inductance and distributed capacitance, thereby improving the transformer's power conversion efficiency and lifespan, and saving costs. This provides a clean, electromagnetically compatible operating environment for the power drive modules of new energy vehicles, thus improving overall vehicle efficiency, extended range, and comfort.

[0060] Example 2

[0061] The difference between this embodiment and embodiment 1 is that in embodiment 2, four shielding layers are provided between the primary winding 2 and the secondary winding 3, and the surface of each shielding layer is wrapped with polyester tape.

[0062] Example 3

[0063] This embodiment is a structural improvement based on embodiment 2. The difference between this embodiment and embodiment 2 is that the secondary winding 3 in embodiment 3 is also wrapped with a shielding layer.

[0064] Example 4

[0065] A voltage converter includes the aforementioned drive shielded transformer.

[0066] The shielded transformer of this application adds a shielding layer between the primary and secondary windings, and the shielding layer is connected to the grounding lead. This shields the parasitic parameters generated during transformer operation, releasing them through the grounding lead. This reduces leakage inductance, distributed capacitance, noise, temperature rise, and electromagnetic interference, while improving power conversion efficiency, insulation, and reliability. The transformer's primary winding is wound on the frame and wrapped with two turns of high-temperature polyester tape. Then, a primary copper foil shielding layer is wound, connected to the grounding lead, and wrapped with two turns of high-temperature polyester tape. A secondary copper foil shielding layer is then wound, connected to the grounding lead, and wrapped with two turns of high-temperature polyester tape. Finally, the secondary winding is wound with three turns of high-temperature polyester tape. The grounding lead of the shielding layer wrapped around the pins and the winding's input and output wires are all wrapped with sleeves, increasing the creepage distance between the pins and improving the transformer's insulation. This prevents breakdown and burnout of the primary and secondary windings due to excessive proximity during operation. To reduce electromagnetic interference between the transformer and other components on the PCB board, a nickel-plated steel sheath is wrapped around the transformer. This effectively shields the transformer from external interference, increases its moisture resistance, protects its internal structure and electrical performance, and provides good compatibility with assembly structures. This invention is particularly suitable for use in power drive modules of precision equipment and instruments such as new energy vehicles, automated equipment, communication equipment, and measuring instruments.

[0067] The above content is only for illustrating the technical concept of this utility model and should not be construed as limiting the scope of protection of this utility model. Any modifications made to the technical solution based on the technical concept proposed in this utility model shall fall within the scope of protection of the claims of this utility model.

Claims

1. A drive shielded transformer, characterized by Includes the frame, primary winding, secondary winding, and magnetic core; The primary winding and secondary winding are sequentially wrapped around the frame, and multiple shielding layers are provided between the primary winding and secondary winding, with an insulating layer between adjacent shielding layers; the magnetic core is located at both ends of the frame, and the leads of the primary winding, secondary winding and shielding layers are connected to the pins of the frame, and the shielding layers are grounded through the pins. The shielding layer includes a primary side shielding layer and a secondary side shielding layer; The primary-side shielding layer is wrapped around the surface of the primary-side winding, and an insulating layer is provided between the primary-side shielding layer and the primary-side winding. The secondary shielding layer is wrapped around the surface of the primary shielding layer, the secondary winding is wound on the outer surface of the secondary shielding layer, and an insulating layer is provided between the primary shielding layer and the secondary shielding layer, and an insulating layer is provided between the secondary shielding layer and the secondary winding. The surface of the secondary winding is provided with a shielding layer; The insulation layer of the lead wire is an insulating sleeve fitted onto the lead wire; The frame is covered with a shielding shell.

2. A drive shielded transformer according to claim 1, characterized in that The shielding shell is a steel-clad clip, which is placed over the frame.

3. A drive shielded transformer according to claim 1, characterized in that The shielding layer is copper foil.

4. A voltage converter, characterized in that, Includes the drive shielded transformer as described in any one of claims 1-3.

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