transformer

Abstract

A transformer comprises a magnetic column, a primary winding comprising a plurality of parallel first coil structures, the plurality of first coil structures being arranged in a nested manner from inside to outside in a first plane, and a secondary winding comprising a plurality of parallel second coil structures, the plurality of second coil structures being arranged in a nested manner from inside to outside in the first plane, wherein the first plane is perpendicular to the extension direction of the magnetic column, and for each of the first coil structures and the second coil structures, the coil structure is wound on the magnetic column and is wound by a flat metal wire with a surface covered with insulation. The disclosed scheme can improve the power of the transformer, reduce the loss power, and has low coil forming difficulty and is easy to manufacture.

Description

Technical Field

[0001] This disclosure relates to the field of transformer technology, and more specifically to a transformer. Background Technology

[0002] Some emerging industries have higher requirements for transformers. For example, artificial intelligence (AI) servers require transformer power that is more than ten times higher than that of ordinary servers. In order to generate higher power, the transformer current needs to be increased. Compared with transformers made of traditional copper wire coils, planar transformers use a single flat metal wire to make a coil, which can increase the current to some extent, but still cannot meet the extremely power-demanding needs of industry applications such as AI servers.

[0003] Existing technologies typically increase the cross-sectional area of ​​the conductor by increasing the width or thickness of the flat wire, thereby increasing the current and power. However, increasing the thickness leads to a corresponding increase in the skin effect, resulting in increased power loss; increasing the width increases the difficulty of coil forming.

[0004] Therefore, there is an urgent need to provide an improved transformer that can balance high power and low manufacturing difficulty. Utility Model Content

[0005] The technical problem solved by this disclosure is to provide an improved transformer.

[0006] To address the aforementioned technical problems, this disclosure provides a transformer, comprising: a magnetic column; a primary winding including a plurality of parallel first coil structures, the plurality of first coil structures being nested from the inside out in a first plane; and a secondary winding including a plurality of parallel second coil structures, the plurality of second coil structures being nested from the inside out in a first plane; wherein, the first plane is perpendicular to the extending direction of the magnetic column, and for each of the first and second coil structures, the coil structure is wound around the magnetic column and is formed by winding a flat metal wire with an insulating material covering its surface.

[0007] Optionally, the primary winding and the secondary winding are alternately arranged along the extension direction of the magnetic post.

[0008] Optionally, for a first coil structure and a second coil structure that are equidistant from the magnetic post in a first plane, the first coil structure and the second coil structure are spaced apart in the extending direction of the magnetic post.

[0009] Optionally, the transformer further includes: baffles sandwiched between the primary winding and the secondary winding.

[0010] Optionally, the baffle is made of an insulating material.

[0011] Optionally, the primary winding includes multiple equivalent coils, wherein each equivalent coil includes a plurality of first coil structures, each located at the same height along the extension direction of the magnetic post, and the width-to-thickness ratio of each equivalent coil is 2:1 to 20:1.

[0012] Optionally, the secondary winding includes multiple equivalent coils, wherein each equivalent coil includes a plurality of second coil structures, each coil portion located at the same height along the extension direction of the magnetic post, and the width-to-thickness ratio of each equivalent coil is 2:1 to 20:1.

[0013] Optionally, the multiple coil portions of each layer of equivalent coil are arranged in concentric rings around the axis of the magnetic column.

[0014] Optionally, each of the first coil structures has the same number of coil turns.

[0015] Optionally, each of the second coil structures has the same number of coil turns.

[0016] Optionally, the number of coil turns in the first coil structure and the number of coil turns in the second coil structure may be the same or different.

[0017] Optionally, the number of multiple first coil structures and the number of multiple second coil structures may be the same or different.

[0018] Optionally, in the plurality of first coil structures, the size of the flat metal wire used to wind at least one first coil structure is different from the size of the flat metal wire used to wind the other first coil structures.

[0019] Optionally, in the plurality of second coil structures, the size of the flat metal wire used to wind at least one second coil structure is different from the size of the flat metal wire used to wind the other second coil structures.

[0020] Compared with the prior art, the technical solutions of the embodiments of this disclosure have the following beneficial effects:

[0021] This disclosure provides a transformer, comprising: a magnetic column; a primary winding including a plurality of first coil structures connected in parallel, the plurality of first coil structures being nested from the inside out in a first plane; and a secondary winding including a plurality of second coil structures connected in parallel, the plurality of second coil structures being nested from the inside out in a first plane; wherein, the first plane is perpendicular to the extending direction of the magnetic column, and for each of the first and second coil structures, the coil structure is wound around the magnetic column and is formed by winding a flat metal wire with an insulating material covering its surface.

[0022] Compared to existing transformers that increase the thickness and / or width of a single flat metal wire to improve power, thus exacerbating the skin effect and increasing the difficulty of coil forming, this embodiment uses multiple first coil structures and multiple second coil structures to lay multiple flat metal wires flat in the same plane. This effectively increases the width of a single layer of winding coil to improve power. Furthermore, since the flat metal wires of each coil structure are wound separately, the transformer provided by this embodiment has lower forming difficulty. Therefore, it can improve transformer power, reduce power loss, and is easy to manufacture with lower coil forming difficulty.

[0023] Furthermore, both the primary and secondary windings are made of flat metal wire, which makes full use of the current resistance of flat metal wire and has a high space utilization rate.

[0024] Furthermore, along the extending direction of the magnetic post, the primary winding and the secondary winding are arranged alternately. This results in better coupling between the primary and secondary windings, which helps reduce AC losses, improve efficiency, and increase power frequency.

[0025] Furthermore, baffles are inserted between the interleaved primary and secondary windings to reduce capacitive coupling between them through physical isolation. This reduces power loss and improves electromagnetic interference. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of a transformer according to the first embodiment of this disclosure;

[0027] Figure 2 yes Figure 1 Exploded view of the transformer shown;

[0028] Figures 3 to 7 This is a schematic diagram of the transformer manufacturing process in a typical application scenario of the first embodiment;

[0029] Figure 8 This is a schematic diagram of the manufacturing process of a transformer according to a second embodiment of the present disclosure;

[0030] Figure 9 This is an exploded view of a transformer according to a third embodiment of this disclosure;

[0031] Figure 10 yes Figure 9 Exploded views of the primary and secondary windings;

[0032] Figure 11 This is a schematic diagram of a transformer according to the fourth embodiment of this disclosure;

[0033] Figure 12 yes Figure 11 A magnified view of a portion of the structure shown. Detailed Implementation

[0034] The embodiments of this utility model will now be described in detail with reference to the accompanying drawings. The same reference numerals are used to denote the same parts in each drawing. The embodiments are merely illustrative, and of course, partial substitutions or combinations can be made to the structures shown in different embodiments. In the variations, descriptions of matters common to Embodiment 1 are omitted, and only the differences are explained. In particular, the same effects produced by the same structure will not be mentioned one by one in each embodiment.

[0035] To make the above-mentioned objectives, features and beneficial effects of this disclosure more apparent and understandable, specific embodiments of this disclosure will be described in detail below with reference to the accompanying drawings.

[0036] The transformer described in this implementation scheme can be applied to industries with high efficiency or power requirements, such as communications, server power supplies, and solar energy. For example, it can be used in the power circuit of an AI server.

[0037] (Example 1)

[0038] Figure 1 This is a schematic diagram of a transformer 1 according to the first embodiment of this disclosure. Figure 2 yes Figure 1 The exploded view of transformer 1 is shown. Figures 3 to 7 This is a schematic diagram of the manufacturing process of transformer 1 in a typical application scenario of the first embodiment.

[0039] Specifically, refer to Figure 1 and Figure 2 The transformer 1 includes a magnetic column 10, a base plate 14, and a cover plate 15. Along the extension direction of the magnetic column 10 (the z-direction in the figure), the base plate 14 and the cover plate 15 are located at both ends of the magnetic column 10.

[0040] For ease of description, on the plane perpendicular to the z-direction (i.e., the first plane), the extension directions of the two sides connected by the base plate 14 are respectively denoted as the x-direction and the y-direction.

[0041] Furthermore, the edge of the base plate 14 along the y-direction can be bent toward the cover plate 15 along the z-direction. The cover plate 15 and the bent section of the base plate 14 abut against each other to close both sides of the magnetic post 10 along the y-direction, thereby forming a closed magnetic flux loop on the plane formed by the y and z directions.

[0042] Furthermore, the magnetic column 10, the base plate 14, and the cover plate 15 are all made of magnetic materials.

[0043] Furthermore, the magnetic post 10 can be connected to the side of the base plate 14 facing the cover plate 15. During assembly, the cover plate 15 and the base plate 14 are fastened together, so that the magnetic post 10 and the surfaces of the cover plate 15 facing the base plate 14 are in contact. Furthermore, an air gap may exist at the contact position between the magnetic post 10 and the cover plate 15, and / or an air gap may exist at the connection between the magnetic post 10 and the base plate 14.

[0044] Furthermore, the transformer 1 also includes a primary winding 11, which comprises a plurality of first coil structures 13 connected in parallel, nested from the inside out within a first plane. Each first coil structure 13 is wound around a magnetic post 10 and is made of flat metal wire with an insulating material covering its surface. Flat metal wire is more resistant to current and has high space utilization. For example, the flat metal wire can be flat copper wire, or it can be a flat aluminum wire or a conductor made of other metal materials.

[0045] For each of the plurality of first coil structures 13, the first coil structure 13 may include multiple layers of coils, which are spirally wound around the magnetic post 10 along the z-direction. The projections of the plurality of first coil structures 13 along the z-direction onto the first plane are arranged in a ring-like sequence from the center of the magnetic post 10 outwards; in other words, the plurality of first coil structures 13 are arranged in concentric rings at the same height along the z-direction with the magnetic post 10 as the center. Among the plurality of first coil structures 13, the innermost first coil structure 13, that is, the one closest to the magnetic post 10, is wound around the magnetic post 10, and the outermost first coil structure 13 is wound around the first coil structure 13 located inside it.

[0046] Furthermore, the primary winding 11, obtained by winding multiple first coil structures 13 side-by-side, includes multiple equivalent coils. Each equivalent coil layer includes coil portions of multiple first coil structures 13 located at the same height along the z-direction; that is, each first coil structure 13 is a single-layer coil at the same height. The multiple coil portions included in each equivalent coil layer are arranged in concentric rings around the axis of the magnetic post 10. The width of each equivalent coil layer is the sum of the widths of the flat metal wires used to wind each first coil structure 13.

[0047] Traditional primary windings are made from a single flat metal wire. The wider the flat metal wire, the more difficult it is to form the primary winding. In contrast, the primary winding 11 in this embodiment is formed by multiple independent first coil structures 13. The width of a single-layer equivalent coil is the sum of the widths of all the flat metal wires. Increasing the number of first coil structures 13, and / or increasing the width of the flat metal wires used to wind the first coil structures 13, can increase the width of the single-layer equivalent coil, meeting the requirements of high-current applications. Furthermore, each first coil structure 13 is independently prepared and wound from flat metal wires, so increasing the width of the single-layer equivalent coil does not increase the difficulty of forming the primary winding 11. Taking a 3000-watt, 48-volt (V) AI server as an example, the transformer needs to be able to withstand a current of 62 amperes (A). Correspondingly, the effective cross-sectional area of ​​the equivalent coil of the primary winding 11 needs to reach 15.6 mm². Using the transformer 1 of Embodiment 1, the current is increased without increasing the thickness of the equivalent coil, providing higher power.

[0048] It should be noted that even if the width of the flat metal wire used to wind the first coil structure 13 is increased to increase the current, under the premise of the same transformer power, the width of any flat metal wire used to wind the primary winding 11 in this embodiment is still significantly smaller than the width of a single flat metal wire used in a conventional primary winding. Assuming that the width of the flat metal wire used to wind each first coil structure 13 is equal, then the width of any flat metal wire used to wind the primary winding 11 in this embodiment is 1 / n of the width of a single flat metal wire used in a conventional primary winding, where n is the number of multiple first coil structures 13.

[0049] In some embodiments, the width-to-thickness ratio of each equivalent coil layer can be from 2:1 to 20:1. The width of each equivalent coil layer is the sum of the widths of the flat metal wires wound around each of the first coil structures 13, where the width of the flat metal wire is its dimension in the first plane perpendicular to the winding direction of the flat metal wire; the thickness of each equivalent coil layer is the thickness of a single flat metal wire, i.e., the dimension of the flat metal wire along the z-direction. Maintaining the thickness of a single equivalent coil layer to the thickness of a single flat metal wire helps to avoid exacerbating the skin effect. In a variation, the thickness of the flat metal wires wound around different first coil structures 13 may be different, in which case the thickness of each equivalent coil layer is the thickness of the thickest flat metal wire among all the flat metal wires of the first coil structures 13.

[0050] Furthermore, the parallel connection of multiple first coil structures 13 is beneficial for increasing the operating current of the transformer 1. For example, each first coil structure 13 may include two taps, namely a current inlet and a current outlet, and the current inlet of multiple first coil structures 13 is connected in parallel, as are the current outlets of multiple first coil structures 13.

[0051] Furthermore, the transformer 1 also includes a secondary winding 12, which includes a plurality of parallel second coil structures 16, which are nested from the inside out in a first plane. Each second coil structure 16 is wound around a magnetic post 10 and is made of flat metal wire with an insulating material covering its surface.

[0052] For each of the plurality of second coil structures 16, the second coil structure 16 may include multiple layers of coils, which are spirally wound around the magnetic post 10 along the z-direction. The projections of the plurality of second coil structures 16 along the z-direction onto the first plane are arranged in a ring outward from the center of the magnetic post 10. In other words, the plurality of second coil structures 16 are arranged in concentric rings at the same height along the z-direction with the magnetic post 10 as the center. Among the plurality of second coil structures 16, the innermost second coil structure 16, that is, the one closest to the magnetic post 10, is wound around the magnetic post 10, and the outermost second coil structure 16 is wound around the second coil structure 16 located inside it.

[0053] Furthermore, the secondary winding 12, obtained by winding multiple second coil structures 16 side-by-side, includes multiple equivalent coils. Each equivalent coil layer includes coil portions of multiple second coil structures 16 located at the same height along the z-direction; that is, each second coil structure 16 is a single-layer coil at the same height. The multiple coil portions included in each equivalent coil layer are arranged in concentric rings around the axis of the magnetic post 10. The width of each equivalent coil layer is the sum of the widths of the flat metal wires used to wind each second coil structure 16.

[0054] Traditional secondary windings are made from a single flat metal wire. The wider the flat metal wire, the more difficult it is to form the secondary winding. In contrast, the secondary winding 12 in this embodiment is formed by multiple independent second coil structures 16. The width of a single-layer equivalent coil is the sum of the widths of all the flat metal wires. Increasing the number of second coil structures 16, and / or increasing the width of the flat metal wires used to wind the second coil structures 16, can increase the width of the single-layer equivalent coil, meeting the requirements of high-current applications. Furthermore, each second coil structure 16 is independently prepared and wound from flat metal wires, so increasing the width of the single-layer equivalent coil does not increase the difficulty of forming the secondary winding 12.

[0055] It should be noted that even if the width of the flat metal wire used to wind the second coil structure 16 is increased to increase the current, under the premise of the same transformer power, the width of any flat metal wire used to wind the secondary winding 12 in this embodiment is still significantly smaller than the width of a single flat metal wire used in a conventional secondary winding. Assuming that the width of the flat metal wire used to wind each second coil structure 16 is equal, then the width of any flat metal wire used to wind the secondary winding 12 in this embodiment is 1 / n of the width of a single flat metal wire used in a conventional secondary winding, where n is the number of the multiple second coil structures 16.

[0056] In some embodiments, the width-to-thickness ratio of each equivalent coil layer can be from 2:1 to 20:1. The width of each equivalent coil layer is the sum of the widths of the flat metal wires wound around each of the second coil structures 16, where the width of the flat metal wire is its dimension in the first plane perpendicular to the winding direction of the flat metal wire; the thickness of each equivalent coil layer is the thickness of a single flat metal wire, i.e., the dimension of the flat metal wire along the z-direction. Maintaining the thickness of a single equivalent coil layer to the thickness of a single flat metal wire helps to avoid exacerbating the skin effect. In a variation, the thickness of the flat metal wires wound around different second coil structures 16 may be different, in which case the thickness of each equivalent coil layer is the thickness of the thickest flat metal wire among all the flat metal wires of the second coil structures 16.

[0057] Furthermore, multiple second coil structures 16 are connected in parallel. For example, each second coil structure 16 may include two taps, namely a current inlet and a current outlet, and the current inlet terminals of multiple second coil structures 16 are connected in parallel, and the current outlet terminals of multiple second coil structures 16 are connected in parallel.

[0058] Example 1 illustrates the following example using a primary winding 11 comprising three first coil structures 13 and a secondary winding 12 comprising three second coil structures 16. Each of the three first coil structures 13 is formed by winding a flat metal wire with an insulating surface. The width of the three flat metal wires can all be L1, and their thicknesses are the same. Correspondingly, the width of a single-layer equivalent coil in the primary winding 11 is 3 × L1, and the thickness of the single-layer equivalent coil is the thickness of the flat metal wire. Similarly, each of the three second coil structures 16 is formed by winding a flat metal wire with an insulating surface. The width of the three flat metal wires is L2, and their thicknesses are the same. Correspondingly, the width of a single-layer equivalent coil in the secondary winding 16 is 3 × L2, and the thickness of the single-layer equivalent coil is the thickness of the flat metal wire. The current input terminals of the three first coil structures 13 are connected in parallel, and the current output terminals of the three second coil structures 16 are connected in parallel. The two taps of the primary winding 11 and the two taps of the secondary winding 12 are located on both sides of the magnetic post 10 along the x-direction.

[0059] Furthermore, along the z-direction, the primary winding 11 and the secondary winding 12 can be staggered. For example, at least a portion of the multiple layers of equivalent coils in the secondary winding 12 are uniformly or non-uniformly arranged between adjacent layers of equivalent coils in the primary winding 11. Embodiment 1 exemplifies this by showing the primary winding 11 and the secondary winding 12 overlapping layer by layer along the z-direction, that is, each layer of equivalent coils in the secondary winding 12 is inserted between adjacent layers of equivalent coils in the secondary winding 11. This results in better coupling between the primary winding 11 and the secondary winding 12, which is beneficial for reducing AC losses, improving efficiency, and increasing power frequency.

[0060] Furthermore, for the first coil structure 13 and the second coil structure 16, which are equidistant from the magnetic post 10 in the first plane, the first coil structure 13 and the second coil structure 16 are arranged at intervals in the z-direction. The three first coil structures 13 included in the primary winding 11 in Embodiment 1 are sequentially referred to from the inside to the outside as the inner first coil structure 131, the middle first coil structure 132, and the outer first coil structure 133; the three second coil structures 16 included in the secondary winding are sequentially referred to from the inside to the outside as the inner second coil structure 161, the middle second coil structure 162, and the outer second coil structure 163. The inner first coil structure 131 and the inner second coil structure 161 are equidistant from the magnetic post 10 in the first plane. The multi-layered coils included in the inner first coil structure 131 and the multi-layered coils included in the inner second coil structure 161 are arranged at regular intervals along the z-direction, with one layer of inner first coil structure 131 coils and one layer of inner second coil structure 161 coils. The intermediate first coil structure 132 and the intermediate second coil structure 162 are equidistant from the magnetic post 10 in the first plane. The multi-layered coils included in the intermediate first coil structure 132 and the multi-layered coils included in the intermediate second coil structure 162 are arranged alternately along the z-direction in a pattern of one layer of coils from the intermediate first coil structure 132 and one layer of coils from the intermediate second coil structure 162. The outer first coil structure 133 and the outer second coil structure 163 are equidistant from the magnetic post 10 in the first plane. The multi-layered coils included in the outer first coil structure 133 and the multi-layered coils included in the outer second coil structure 163 are stacked alternately along the z-direction in a pattern of one layer of coils from the outer first coil structure 133 and one layer of coils from the outer second coil structure 163.

[0061] Furthermore, the number of turns in each of the first coil structures 13 can be the same to avoid circulating current. For example, the inner first coil structure 131, the middle first coil structure 132, and the outer first coil structure 133 each have the same number of turns.

[0062] Furthermore, the winding density of each first coil structure 13 can be the same.

[0063] Furthermore, the number of turns in each of the second coil structures 16 can be the same to avoid circulating current. For example, the inner second coil structure 161, the middle second coil structure 162, and the outer second coil structure 163 each have the same number of turns.

[0064] Furthermore, the winding directions of each first coil structure 13 are the same. The winding directions of each second coil structure 16 are also the same. In some embodiments, the winding directions of the first coil structure 13 and the second coil structure 16 can be the same or opposite.

[0065] Furthermore, the number of turns in the first coil structure 13 and the second coil structure 16 can be the same. Thus, the primary winding 11 and the secondary winding 12 are at the same height along the z-direction, which helps to fully utilize the space enclosed by the base plate 14 and the cover plate 15, improving space utilization.

[0066] It should be noted that the illustrations are only illustrative of the first coil structure 13 and the second coil structure 16. In practical applications, those skilled in the art can adjust the number of coil turns and the winding density of the first coil structure 13 and the second coil structure 16 as needed.

[0067] Furthermore, the number of multiple first coil structures 13 and the number of multiple second coil structures 16 can be the same. For example, the primary winding 11 includes three first coil structures 13 and the secondary winding 12 includes three second coil structures 16.

[0068] Therefore, by adopting this embodiment, multiple first coil structures 13 and multiple second coil structures 16 are arranged to lay multiple flat metal wires in the same plane, effectively increasing the width of a single layer of winding coil to improve power. Furthermore, since the flat metal wires of each coil structure are wound separately, the transformer 1 provided by this embodiment has low molding difficulty. Thus, the power of transformer 1 can be increased, power loss can be reduced, and the coil molding difficulty is low, making it easy to manufacture.

[0069] In a typical application scenario, the manufacturing process of transformer 1 may include the following steps (referred to as S):

[0070] S1, three first coil structures 13 are obtained by winding the inner first coil structure 131, the middle first coil structure 132, and the outer first coil structure 133 respectively, as follows: Figure 3 As shown, the areas of the hollow portions of the inner first coil structure 131, the middle first coil structure 132, and the outer first coil structure 133 increase sequentially.

[0071] S2, the coil portion of the middle first coil structure 132 is embedded into the hollow portion of the outer first coil structure 133, and the coil portion of the inner first coil structure 131 is embedded into the hollow portion of the middle first coil structure 132, thus obtaining the primary winding 11, as follows. Figure 4 As shown. Along the winding direction of the coil, the current lead-out terminals of the three first coil structures 13 are located on the same side, and the current lead-in terminals are also located on the same side, and the current lead-out terminals and the current lead-in terminals are respectively drawn out from both sides of the coil section.

[0072] For any one of the inner first coil structure 13, the middle first coil structure 132, and the outer first coil structure 133, a non-zero gap may exist between any two adjacent layers of coils in the first coil structure 13. Correspondingly, each layer of equivalent coils in the primary winding 11 has a non-zero gap. The size of the gap can be from 1.5 to 2.3 mm.

[0073] S3, three second coil structures 16 are obtained by winding the inner second coil structure 161, the middle second coil structure 162, and the outer second coil structure 163 respectively, as follows: Figure 5 As shown, the areas of the hollow portions of the inner second coil structure 161, the middle second coil structure 162, and the outer second coil structure 163 increase sequentially.

[0074] S4, embed the coil portion of the middle second coil structure 162 into the hollow portion of the outer second coil structure 163, and embed the coil portion of the inner second coil structure 161 into the hollow portion of the middle second coil structure 162 to obtain the secondary winding 12, as follows. Figure 6 As shown. Along the winding direction of the coil, the current lead-out terminals of the three second coil structures 16 are located on the same side, and the current lead-in terminals are also located on the same side, and the current lead-out terminals and the current lead-in terminals are respectively drawn out from both sides of the coil section.

[0075] For any of the inner second coil structure 16, the middle second coil structure 162, and the outer second coil structure 163, a spacing of 1.5 to 2.3 mm may exist between any two adjacent layers of coils in the second coil structure 16. Correspondingly, a spacing of 1.5 to 2.3 mm may exist between two adjacent layers of equivalent coils in the secondary winding 12.

[0076] S5, embed each layer of equivalent coil of the secondary winding 12 between two adjacent layers of equivalent coil of the primary winding 11, such as... Figure 7 As shown.

[0077] S6, place the overlapping primary winding 11 and secondary winding 12 onto the base plate 14, with the hollow portion formed by the primary winding 11 and secondary winding 12 nested within the magnetic post 10 connected to the base plate 14. Cover with the cover plate 15, resulting in... Figure 1 Transformer 1 is shown.

[0078] In one variation, among the plurality of first coil structures 13, the dimensions of the flat metal wire used to wind at least one first coil structure 13 may differ from the dimensions of the flat metal wire used to wind the other first coil structures 13. For example, the width of the flat metal wire used to wind the inner first coil structure 131 is greater than the width of the flat metal wire used to wind the middle first coil structure 132, while the width of the flat metal wire used to wind the middle first coil structure 132 is consistent with the width of the flat metal wire used to wind the outer first coil structure 133. Another example is that the thickness of the flat metal wire used to wind the inner first coil structure 131 is greater than the thickness of the flat metal wire used to wind the middle first coil structure 132, which in turn is greater than the thickness of the flat metal wire used to wind the outer first coil structure 133.

[0079] Similarly, in the plurality of second coil structures 16, the dimensions of the flat metal wire used to wind at least one second coil structure 16 may differ from the dimensions of the flat metal wire used to wind the other second coil structures 16. For example, the width of the flat metal wire used to wind the intermediate second coil structure 162 is greater than the width of the flat metal wire used to wind the inner second coil structure 161, while the width of the flat metal wire used to wind the inner second coil structure 161 is consistent with the width of the flat metal wire used to wind the outer second coil structure 163. As another example, the thickness of the flat metal wire used to wind the inner second coil structure 161 is less than the thickness of the flat metal wire used to wind the intermediate second coil structure 162, which is less than the thickness of the flat metal wire used to wind the outer second coil structure 163.

[0080] For example, the flat metal wires used to wind the three first coil structures 13 are of equal size, and the flat metal wires used to wind the three second coil structures 16 are also of equal size, but the width of the flat metal wires used to wind the three first coil structures 13 is different from the width of the flat metal wires used to wind the three second coil structures 16, and / or, the thickness of the flat metal wires used to wind the three first coil structures 13 is different from the thickness of the flat metal wires used to wind the three second coil structures 16.

[0081] In one variation, the number of turns in the first coil structure 13 and the number of turns in the second coil structure 16 may be different. For example, the number of turns in a single first coil structure 13 may be greater than the number of turns in a single second coil structure 16, or vice versa.

[0082] (Example 2)

[0083] Figure 8 This is a schematic diagram of the manufacturing process of a transformer 2 according to the second embodiment of this disclosure.

[0084] In this embodiment, the main difference from Embodiment 1 is that the primary winding 21 includes two first coil structures 13, and the secondary winding 22 includes two second coil structures 16. Compared to Embodiment 1, this embodiment further reduces manufacturing complexity by reducing the number of structures. Simultaneously, by appropriately selecting a wider flat metal wire to wind the first coil structures 13 and the second coil structures 16, the effective cross-sectional area of ​​the primary winding 21 and the secondary winding 22 is avoided, ensuring that the transformer 2 can generate sufficiently large power.

[0085] For ease of description, the two first coil structures 13 are referred to as the inner first coil structure 131 and the outer first coil structure 133, respectively, and the two second coil structures 16 are referred to as the inner second coil structure 161 and the outer second coil structure 163, respectively.

[0086] In a typical application scenario, the manufacturing process of transformer 2 may include the following steps:

[0087] S1, two first coil structures 13 are obtained by winding the inner first coil structure 131 and the outer first coil structure 133 respectively, as follows: Figure 8 As shown in view (a), the area of ​​the hollow portion of the inner first coil structure 131 is smaller than the area of ​​the hollow portion of the outer first coil structure 133.

[0088] S2, the coil portion of the inner first coil structure 131 is embedded into the hollow portion of the outer first coil structure 133 to obtain the primary winding 21, as shown. Figure 8 As shown in view (b). Along the winding direction of the coil, the current lead-out terminals of the two first coil structures 13 are located on the same side, and the current lead-in terminals are also located on the same side, and the current lead-out terminals and the current lead-in terminals are respectively drawn out from both sides of the coil portion.

[0089] For either the inner first coil structure 131 or the outer first coil structure 133, a non-zero gap may exist between any two adjacent layers of coils in the first coil structure 13. Correspondingly, each layer of equivalent coils in the primary winding 21 has a non-zero gap. The size of the gap may range from 1.5 to 2.3 mm.

[0090] S3, two second coil structures 16 are obtained by winding the inner second coil structure 161 and the outer second coil structure 163 respectively, as follows: Figure 8 As shown in view (c), the area of ​​the hollow portion of the inner second coil structure 161 is smaller than the area of ​​the hollow portion of the outer second coil structure 163.

[0091] S4, the coil portion of the inner second coil structure 161 is embedded into the hollow portion of the outer second coil structure 163 to obtain the secondary winding 22, as shown. Figure 8 As shown in view (d). Along the winding direction of the coil, the current leads of the two second coil structures 16 are located on the same side, and the current leads are also located on the same side, and the current leads and current leads are drawn out from both sides of the coil section respectively.

[0092] For either the inner second coil structure 161 or the outer second coil structure 163, a spacing of 1.5 to 2.3 mm may exist between any two adjacent layers of coils in the second coil structure 16. Correspondingly, a spacing of 1.5 to 2.3 mm exists between any two adjacent layers of equivalent coils in the secondary winding 22.

[0093] S5, embed each layer of equivalent coil of the secondary winding 22 between two adjacent layers of equivalent coil of the primary winding 21, such as... Figure 8 As shown in view (e).

[0094] S6, along the z-direction, the overlapping primary winding 21 and secondary winding 22, along with the cover plate 15, are placed onto the base plate 14 to obtain transformer 2, as shown. Figure 8 The view shown in (f) is shown.

[0095] (Example 3)

[0096] Figure 9 This is an exploded view of a transformer 3 according to a third embodiment of this disclosure. Figure 10 yes Figure 9 Exploded view of the primary winding 31 and the secondary winding 32.

[0097] In this embodiment, the main difference from Embodiment 1 is that the number of the plurality of first coil structures 13 and the number of the plurality of second coil structures 16 are different. For example, the primary winding 31 includes two first coil structures 13, and the secondary winding 32 includes three second coil structures 16.

[0098] For ease of description, the two first coil structures 13 are referred to as the middle first coil structure 132 and the outer first coil structure 133, and the three second coil structures 16 are referred to as the inner second coil structure 161, the middle second coil structure 162 and the outer second coil structure 163.

[0099] Furthermore, the intermediate first coil structure 132 and the intermediate second coil structure 162 are interleaved, and the outer first coil structure 133 and the outer second coil structure 163 are interleaved. There are no other structures (e.g., coils of the first coil structure 13) inserted between adjacent layers of coils in the inner second coil structure 161.

[0100] Therefore, the number of coil structures on the primary and secondary sides can be flexibly adjusted as needed to independently adjust the current on the primary and secondary sides.

[0101] (Example 4)

[0102] Figure 11 This is a schematic diagram of a transformer 4 according to the fourth embodiment of this disclosure. Figure 12 yes Figure 11 A partially enlarged view of the structure shown. To more clearly illustrate the structure of the transformer 4 described in this embodiment, Figure 11 and Figure 12 The magnetic column 10, the base plate 14, and the cover plate 15 are not shown.

[0103] In this embodiment, the main difference from Embodiment 1 is that the transformer 4 further includes a baffle 17 sandwiched between the primary winding 11 and the secondary winding 12. Specifically, the baffle 17 can be U-shaped, with a single-layer equivalent coil of the primary winding 11 or the secondary winding 12 inserted through the opening of the U-shape, thereby blocking the two adjacent layers of equivalent coils. One of the two adjacent layers of equivalent coils belongs to the primary winding 11, and the other belongs to the secondary winding 12.

[0104] Furthermore, the baffle 17 can be made of insulating material.

[0105] Therefore, by physically isolating the primary winding 11 and the secondary winding 12, capacitive coupling is reduced, power loss is decreased, and electromagnetic interference is improved. The transformer 4 in this embodiment can be applied to high-voltage scenarios.

[0106] While the above disclosure is provided, it is not limited thereto. Any person skilled in the art may make various alterations and modifications without departing from the spirit and scope of this disclosure; therefore, the scope of protection of this disclosure shall be determined by the scope defined in the claims.

[0107] Explanation of reference numerals in the attached figures

[0108] Transformers 1, 2, 3, and 4

[0109] 10 magnetic columns

[0110] Primary windings 11, 21, 31

[0111] 12, 22, 32 secondary windings

[0112] 13 First coil structure

[0113] 131 Inner First Coil Structure

[0114] 132 Middle First Coil Structure

[0115] 133 Outer First Coil Structure

[0116] 14. Base Plate

[0117] 15 Cover plate

[0118] 16 Second Coil Structure

[0119] 161 Inner Second Coil Structure

[0120] 162. Middle Second Coil Structure

[0121] 163 Outer Second Coil Structure

[0122] 17 baffles

[0123] The widths of L1 and L2 flat metal wires

Claims

1. A transformer, characterized in that, include: Magnetic column; The primary winding includes multiple parallel first coil structures, which are nested from the inside to the outside in a first plane. The secondary winding includes multiple parallel second coil structures, which are nested from the inside to the outside in a first plane; Wherein, the first plane is perpendicular to the extension direction of the magnetic column, and for each of the first coil structure and the second coil structure, the coil structure is wound around the magnetic column and is made of flat metal wire with an insulating material covering its surface.

2. The transformer according to claim 1, characterized in that, Along the extension direction of the magnetic column, the primary winding and the secondary winding are arranged alternately.

3. The transformer according to claim 2, characterized in that, For a first coil structure and a second coil structure that are equidistant from the magnetic post in a first plane, the first coil structure and the second coil structure are spaced apart in the extending direction of the magnetic post.

4. The transformer according to claim 2, characterized in that, Also includes: A baffle is sandwiched between the primary winding and the secondary winding.

5. The transformer according to claim 4, characterized in that, The baffle is made of insulating material.

6. The transformer according to claim 1, characterized in that, The primary winding comprises multiple equivalent coils, wherein each equivalent coil layer includes multiple first coil structures, each consisting of coil portions at the same height along the extension direction of the magnetic post, and the width-to-thickness ratio of each equivalent coil layer is 2:1 to 20:1; and / or The secondary winding includes multiple equivalent coils, wherein each equivalent coil includes multiple second coil structures, each coil portion located at the same height along the extension direction of the magnetic post, and the width-to-thickness ratio of each equivalent coil is 2:1 to 20:

1.

7. The transformer according to claim 6, characterized in that, Each layer of equivalent coil includes multiple coil portions arranged in concentric rings around the axis of the magnetic column.

8. The transformer according to claim 1, characterized in that, The number of coil turns in each of the first coil structures is the same; and / or, the number of coil turns in each of the second coil structures is the same; and / or, the number of coil turns in the first coil structure and the number of coil turns in the second coil structure are the same or different.

9. The transformer according to claim 1, characterized in that, The number of multiple first coil structures and the number of multiple second coil structures may be the same or different.

10. The transformer according to claim 1, characterized in that, In a plurality of first coil structures, the dimensions of the flat metal wire used to wind at least one first coil structure are different from the dimensions of the flat metal wire used to wind the other first coil structures; and / or In a plurality of second coil structures, the size of the flat metal wire used to wind at least one second coil structure is different from the size of the flat metal wire used to wind the other second coil structures.

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