Vertical high voltage transformer, high voltage transformer skeleton and switching power supply

Abstract

The utility model discloses a vertical high voltage transformer, high voltage transformer framework and switching power supply, the vertical high voltage transformer, including framework, a plurality of windings and magnetic core, and framework includes winding post and the through -hole of setting up in the middle part of winding post, a plurality of windings are wound on the winding post of framework, and the magnetic core is into the through -hole of framework, its characterized in that: still include shielding layer, set up between the primary winding and the secondary winding, and its first end and tail end have no electrical connection, and is equipped with the lead -out wire, is used to connect the ground through the lead -out wire, a plurality of windings, including the first winding, the second winding, the third winding and the fourth winding of primary side and the secondary winding, and the first winding and the second winding of primary side are separated and are wound in the same layer in the way of separating line and pull out four wire ends, are used for fixedly connected with four transformer pin respectively. The utility model discloses through a series of methods and structure optimization, and the product design of vertical high voltage transformer is more miniaturized, and can improve the comprehensive performance of power supply product significantly.

Description

Technical Field

[0001] This utility model relates to the technical field of transformer structure in switching power supplies, and in particular to a vertical high-voltage transformer, a high-voltage transformer frame, and a switching power supply. Background Technology

[0002] Existing switching power supply products with wide input voltage ranges and high maximum input voltages commonly employ a multi-transistor series flyback circuit topology to meet high voltage withstand requirements. However, due to limitations in the number of transformer windings and differences in transformer coupling performance, the number of input circuits in series cannot be infinitely large. In multi-stage series connection, the turns ratio of the transformer input windings and output windings in each stage of the input circuit is the same, and the switching transistors in each stage of the input circuit are turned on simultaneously. Commonly used circuit schematics are shown below. Figure 1 As shown, a multi-transistor series flyback circuit mainly includes power transistors Q1, Q2, Q3, and Q4, and a high-voltage transformer T1. The high-voltage transformer T1 includes a primary winding P1, a secondary winding P2, a third winding P3, a fourth winding P4, and a secondary winding S1. A conventional high-voltage transformer includes a frame, multiple windings, and a magnetic core. The frame includes winding posts and through holes in the middle of the winding posts. Multiple windings are wound on the winding posts of the frame, and the magnetic core is inserted into the through holes of the frame.

[0003] Traditional high-voltage transformers use a sandwich winding method, where a primary winding is wound with one layer of insulating paper and then a secondary winding is wound with another layer of insulating paper; this winding method is repeated to form the entire transformer winding coil. The resulting winding structure is as follows: Figure 2 As shown, specifically, the first winding P1 of the primary side is wound as one layer to form the innermost winding N1. Part of the winding of the secondary side S1 is wound as one layer to form the inner second winding N2. The second winding P2 of the primary side is wound as one layer to form the inner third winding N3. Part of the winding of the secondary side S1 is wound as one layer to form the inner fourth winding N4. The third winding P3 is wound as one layer to form the inner fifth winding N5. Part of the winding of the secondary side S1 is wound as one layer to form the inner sixth winding N6. The fourth winding P4 is wound as one layer to form the inner seventh winding N7. Since the secondary side winding S1 is a winding structure, it is wound separately in the inner second winding N2, the inner fourth winding N4, and the inner sixth winding N6, and finally connected in parallel to form a single winding. In this type of transformer winding method, the insulation between the primary and secondary windings relies on the insulation material of the wires themselves and the yellow insulating tape between the windings. Currently, the small-volume high-voltage transformers commonly found on the market, due to the limited space in their size design, rely on a simple combination of wires and insulating tape for insulation, which is far from meeting the electrical isolation safety performance requirements of the national standard GB3836.4 (Chinese standard name: Explosive Atmospheres Part 4: Equipment Protected by Intrinsically Safe "i"). Utility Model Content

[0004] This utility model optimizes the structure to reduce the size of the vertical transformer and meets the certification requirements of the national standard GB3836.4. Therefore, the structure of this utility model can significantly improve the isolation performance of power supply products and make the product design more compact.

[0005] To achieve the above-mentioned objectives, the present invention provides the following technical solution: A vertical high-voltage transformer, suitable for multi-winding transformer applications with multi-tube series flyback circuits, includes a frame, multiple windings, and a magnetic core. The frame includes winding posts and through holes in the middle of the winding posts. Multiple windings are wound on the winding posts of the frame, and the magnetic core is inserted into the through holes of the frame. The transformer is characterized by further including a shielding layer, which is disposed between the primary winding and the secondary winding. Its start and end ends are not electrically connected, and it is provided with lead wires for connecting to the ground. Multiple windings, including primary windings 1, 2, 3, and 4, and a secondary winding. The primary windings 1 and 2 are wound side-by-side in the same layer with four wire ends, each for fixed connection to one of the four transformer pins. The primary windings 3 and 4 are wound side-by-side in the same layer with four wire ends, each for fixed connection to one of the four transformer pins. The secondary winding is wound in layers and has two wire ends, each for fixed connection to one of the two transformer pins. The first and second windings of the primary side are wound on the innermost layer, and the first shielding layer is wound on the first and second windings of the primary side; the secondary winding is wound on the first shielding layer; the second shielding layer is wound on the secondary winding layer; the third and fourth windings of the primary side are wound on the second shielding layer.

[0006] Preferably, the secondary winding includes a first winding and a second winding. The first and second windings of the secondary winding are wound on the same layer and then two wire ends are pulled out for fixed connection with two transformer pins respectively.

[0007] Preferably, insulating tape is added between the primary and secondary windings to improve the insulation performance between the primary and secondary windings; and / or a sleeve is added to the wire of one, several or all of the multiple windings.

[0008] Preferably, the first, second, third, and fourth windings of the primary side are made of triple-insulated wire, and the first and second windings of the secondary side are made of Litz wire.

[0009] Preferably, the shielding layer is made of copper foil; and / or the thickness of the shielding layer is determined by the primary current.

[0010] Preferably, the frame is provided with winding posts, which are designed to be taller, so as to make the effective window area coefficient of the transformer more reasonable when the winding structure of the primary and secondary sides is stacked.

[0011] Preferably, the frame is provided with a terminal block, and metal pins extend from both sides of the terminal block for fixed connection with the winding ends of the transformer; and / or a baffle is provided in the gap next to the winding structure with multiple windings wound in the same layer, so as to fill the winding area in the same layer and facilitate the shielding layer to be wound more smoothly around it.

[0012] This utility model also provides a vertical high-voltage transformer, which is suitable for multi-winding transformer applications with multi-tube series flyback circuits. It includes a frame, multiple windings and a magnetic core. The frame includes a winding post and a through hole in the middle of the winding post. Multiple windings are wound on the winding post of the frame. The magnetic core is inserted into the through hole of the frame. It also includes a copper foil layer, which is disposed between the primary winding and the secondary winding. Its first and last ends are not electrically connected, and it is provided with lead wires for connecting to the ground. Multiple windings, including the first, second, third, and fourth windings on the primary side and the secondary winding, wherein the first and second windings on the primary side are wound on the bobbin winding posts to form the innermost winding, and the first copper foil layer is wound on the innermost winding; the secondary winding is wound on the first copper foil layer; the second copper foil layer is wound on the secondary winding layer; and the third and fourth windings on the primary side are wound on the second copper foil layer.

[0013] Preferably, the first and second windings of the primary side are wound in parallel on the same layer and then four wire ends are pulled out for fixed connection with the four transformer pins respectively; or the first and second windings of the primary side are wound in parallel on the same layer and then four wire ends are pulled out for fixed connection with the four transformer pins respectively.

[0014] Preferably, the third and fourth windings of the primary side are wound in parallel on the same layer and then four wire ends are pulled out for fixed connection with the four transformer pins respectively; or the third and fourth windings of the primary side are wound in parallel on the same layer and then four wire ends are pulled out for fixed connection with the four transformer pins respectively.

[0015] Preferably, the secondary winding includes a first winding and a second winding. The first and second windings of the secondary winding are wound on the same layer and then two wire ends are pulled out for fixed connection with two transformer pins respectively; or the first and second windings of the secondary winding are wound side by side on the same layer in a split manner and then two wire ends are pulled out for fixed connection with two transformer pins respectively.

[0016] Preferably, the primary windings (first, second, third, and fourth) are made of triple-insulated wire, and the secondary winding is made of Litz wire; and / or the frame is provided with winding posts, which are designed to be taller, in order to achieve a transformer effective window area coefficient in the miniaturized design of the primary and secondary layered winding structure. More reasonable.

[0017] Preferably, insulating tape is added between the primary and secondary windings to improve the insulation performance between them; and / or a baffle is provided at the gap next to the winding structure of the innermost winding, the secondary winding layer, and the third and fourth winding layers of the primary side to fill the winding area of ​​the same layer so that the shielding layer can be wound more smoothly around it; and / or a sleeve is added to the wires of the first, second, third, and fourth windings of the primary side and / or the secondary windings; and / or the frame is provided with a terminal block, with metal pins extending from both sides of the terminal block for fixed connection with the winding wire ends of the transformer.

[0018] This utility model provides a vertical high-voltage transformer suitable for multi-winding transformer applications with multi-tube series flyback circuits. It includes a frame, multiple windings, and a magnetic core. The frame includes winding posts and through holes in the middle of the winding posts. Multiple windings are wound on the winding posts of the frame. The magnetic core is inserted into the through holes of the frame. It also includes a copper foil layer, which is disposed between the primary winding and the secondary winding. Its first and last ends are not electrically connected, and it is provided with lead wires for connecting to the ground. Multiple windings, including a primary winding, a second winding, and a secondary winding, wherein the primary winding is wound on the bobbin winding post to form the innermost winding, and a first copper foil layer is wound on the innermost winding; the secondary winding is wound on the first copper foil layer; a second copper foil layer is wound on the secondary winding layer; and the primary winding is wound on the second copper foil layer.

[0019] This utility model provides another high-voltage transformer frame, applicable to the above-mentioned vertical high-voltage transformer, including winding posts, characterized in that: the winding posts adopt an increased height design, so as to achieve a more reasonable effective window area coefficient of the transformer when the primary and secondary winding structure is miniaturized.

[0020] Preferably, the winding post of the skeleton is increased to about twice the height of the existing skeleton winding post; and / or the skeleton is provided with a terminal block, with metal pins extending from both sides of the terminal block for fixed connection with the winding wire end of the transformer.

[0021] This utility model provides another switching power supply, including the above-mentioned vertical high-voltage transformer. The vertical high-voltage transformer is mounted on a PCB circuit board and packaged into a switching power supply with a multi-tube series flyback circuit topology of up to 350W. Its primary and secondary electrical isolation can reach 5000VAC and can meet the certification requirements of national standard GB3836.4.

[0022] This utility model provides another switching power supply, including the above-mentioned vertical high-voltage transformer. The vertical high-voltage transformer is mounted on a PCB circuit board and packaged into a switching power supply of up to 350W. Its primary and secondary electrical isolation can reach 5000VAC.

[0023] This utility model further provides a switching power supply, including the above-mentioned vertical high-voltage transformer, wherein the vertical high-voltage transformer is mounted on a PCB circuit board and packaged to form a switching power supply of up to 350W.

[0024] Compared with traditional transformers, the advantages of this vertical high-voltage transformer are: 1. By optimizing the winding structure and designing a suitable transformer frame, the primary and secondary electrical isolation of this type of transformer with added shielding layer can reach 5000VAC. 2. With the product design becoming more miniaturized, the increased winding window area reduces the difficulty of the winding process, and the related temperature control can be comparable to or better than that of traditional transformers. 3. Applicable to multi-transistor series flyback circuit topology switching power supplies up to 350W; 4. Because the spacing between the primary windings is closer, the transformer has less leakage inductance and less noise when withstand voltage testing. This makes the overall performance of the power supply product significantly improved and meets the certification requirements of the national standard GB3836.4 for power supply products in coal mines. Compared with traditional transformers, it can better meet market demands. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of a commonly used multi-transistor series flyback circuit. Figure 2 This is a schematic diagram of the winding structure of a traditional transformer; Figure 3 This is a schematic diagram of the winding structure of the vertical high-voltage transformer of the present invention; Figure 4 This is a three-dimensional structural diagram of the vertical high-voltage transformer of the present invention, wherein the outer layer of insulating paper of the transformer winding coil is peeled off to expose the inner layer of wire; the pull-out end of the winding is schematic and the wire diameter is not shown. Figure 5This is a three-dimensional structural view of the vertical high-voltage transformer of the present invention from another perspective, wherein the outer layer of insulating paper of the transformer winding coil is peeled off to expose the inner layer of wire; the pull-out end of the winding is schematic and the wire diameter is not shown. Figure 6 This is a three-dimensional structural diagram of the frame of the vertical high-voltage transformer of the present invention; Figure 7 This is a three-dimensional structural diagram of the frame of the vertical high-voltage transformer of the present invention from another perspective. Figure 8 This is a schematic diagram of the winding structure of the frame of the vertical high-voltage transformer of the present invention, which has an innermost winding and a first shielding layer wound on it. Figure 9 This is a test diagram of the stress waveform of the main power MOSFET in a traditional high-voltage transformer. Figure 10 This is a test diagram of the stress waveform of the main power MOSFET of the vertical high-voltage transformer of the present invention.

[0026] The reference numerals in the above figures are explained as follows: 100. Frame, 101. Winding post, 102. Terminal block, 103. Metal lead, 104. Through hole 200. Winding, 201. Primary winding P1 (N1), 202. Primary winding P2 (N2), 203. Primary winding P3 (N5), 204. Primary winding P4 (N6), 210. Secondary winding S1 (secondary winding N3, secondary winding N4), where the numbers in parentheses are the numbers in the corresponding winding structure diagram. 300. Magnetic core 400. Shielding layer; 401. Lead wire; 411. First shielding layer; 412. Second shielding layer 500. Insulating tape 600. Retaining wall 700. Casing Detailed Implementation Invention concept description: A common flyback circuit uses multiple transistors connected in series. In a traditional transformer, the four primary windings and three secondary windings are sandwich-wound, with each winding occupying one layer of the bobbin winding area. The specific winding structure is: primary-secondary-primary-secondary-primary-secondary-primary-secondary-primary-auxiliary-primary-auxiliary-primary-auxiliary-auxiliary winding (e.g., ...). Figure 2 (As shown).

[0027] This utility model of a vertical high-voltage transformer features a sandwich winding method for its four primary windings and three secondary windings. The first and second primary windings are on the same layer, sharing the same winding area on the bobbin winding column, with each winding occupying half of the winding area on the same layer. The three secondary windings are wound in parallel. The third and fourth primary windings are on the same layer, sharing the same winding area on the bobbin winding column, with each winding occupying half of the winding area on the same layer. A shielding layer, such as copper foil, is provided between the primary and secondary windings. The specific winding structure is: primary / primary-copper foil-secondary / secondary / secondary / -copper foil-primary / primary (e.g., ...). Figure 3 (As shown).

[0028] This utility model of a vertical high-voltage transformer optimizes the winding structure and process, and designs a suitable transformer frame, making the product design of this type of transformer with added shielding layer more compact. The leakage inductance and temperature control of the transformer can be comparable to those of traditional transformers, and it can significantly improve the isolation performance of power supply products, and meet the requirements of coal-fired power plants. The national standard GB3836.4 for mining specifies the certification requirements for intrinsically safe insulation of products.

[0029] The present invention and its beneficial effects will be further described in detail below with reference to specific embodiments and accompanying drawings. However, the specific embodiments of the present invention are not limited thereto.

[0030] Please see Figures 3 to 8 This utility model discloses a vertical high-voltage transformer suitable for multi-winding transformer applications with multi-tube series flyback circuits. It includes a frame 100, multiple windings 200, and a magnetic core 300. The frame includes a winding post 101 and a through hole 104 in the middle of the winding post. Multiple windings are wound on the winding post of the frame. The magnetic core is inserted into the through hole of the frame. It also includes a shielding layer 400, which is disposed between the primary winding and the secondary winding. Its first and last ends are not electrically connected. It is provided with a lead wire 401 (shown schematically in the figure, the wire diameter and specific structure are not shown) for connecting to the ground through the lead wire. Multiple windings, including primary winding 201, 202, 203, and 204, and secondary winding 210. Primary windings 201 and 202 are wound side-by-side in the same layer with four wire ends, which are then pulled out for fixed connection to four transformer pins. Primary windings 203 and 204 are also wound side-by-side in the same layer with four wire ends, which are then pulled out for fixed connection to four transformer pins. Secondary winding 210 is wound in layers and then has two wire ends pulled out. Used for fixed connection to the pins of two transformers respectively; where... The first winding 201 and the second winding 202 of the primary side are wound on the innermost layer, and the first shielding layer 411 is wound on the first winding and the second winding of the primary side; the secondary winding 210 is wound on the first shielding layer 411; the second shielding layer 412 is wound on the secondary winding layer; the third winding 203 and the fourth winding 204 of the primary side are wound on the second shielding layer 412.

[0031] Preferably, the secondary winding 210 includes a first winding N3 and a second winding N4. The first winding N3 and the second winding N4 of the secondary side are wound simultaneously in the same layer and then pulled out to have two wire ends for fixed connection with two transformer pins respectively. Insulating tape 500 is added between the primary and secondary windings to improve the insulation performance between the primary and secondary sides; and / or the wire of one, several, or all of the windings is provided with a sleeve. The first, second, third, and fourth windings of the primary side are made of triple-insulated wire, and the first and second windings of the secondary side are made of Litz wire. The shielding layer 400 is made of copper foil; and / or the thickness of the shielding layer is determined by the primary current.

[0032] The frame includes winding posts 101, which are designed with increased height to achieve a more reasonable effective window area factor for the transformer in the miniaturized design of the primary and secondary side stacked winding structure. In this embodiment, a more reasonable effective window area factor in the miniaturized design of the primary and secondary side stacked winding structure can be based on the maximum effective window area factor of the stacked winding structure. The innermost layer size determines the winding structure. The innermost layer size is the height of the two windings that are wound side-by-side with their wires and sides split.

[0033] The secondary winding terminals of the transformer core use Litz wire (a single conductor made of multiple independently insulated conductors twisted or braided together), which has a thicker diameter. To simplify the transformer's structural design, the terminals of the secondary winding can generally be directly pulled out as external leads (i.e., transformer pins, soldering leads used for electrical connection to the PCB board). However, due to differences in the secondary winding wire diameter among different power supply models, the soldering positions of the transformer pins on the corresponding PCB board need to be adjusted accordingly, leading to poor PCB board design consistency and hindering the transformer's downstream applications. For example... Figure 6 and Figure 7 As shown, the preferred frame of the vertical high-voltage transformer of the present invention is provided with a terminal block 102, and metal pins 103 extend from both sides of the terminal block for fixed connection with the winding ends of the transformer.

[0034] In other embodiments, the specific structure of each layer in the sandwich winding method can be flexibly configured according to the product performance design requirements.

[0035] Based on the inventive concept, a vertical high-voltage transformer is suitable for multi-winding transformer applications with multi-tube series flyback circuits. It includes a frame 100, multiple windings 200, and a magnetic core 300. The frame includes a winding post 101 and a through hole 104 opened in the middle of the winding post. Multiple windings are wound on the winding post of the frame. The magnetic core is inserted into the through hole of the frame. It also includes a copper foil layer, which is set between the primary winding and the secondary winding. Its first and last ends are not electrically connected. It is provided with a lead wire 401 for connecting to the ground through the lead wire. Multiple windings, including a primary winding 201, a second winding 202, a third winding 203, and a fourth winding 204, and a secondary winding 210, wherein the primary winding 201 and the second winding are wound on the bobbin winding post to form the innermost winding, and the first copper foil layer is wound on the innermost winding; the secondary winding is wound on the first copper foil layer; the second copper foil layer is wound on the secondary winding layer; and the primary winding 210 and the third winding and the fourth winding are wound on the second copper foil layer.

[0036] There are several ways to further wind the primary winding.

[0037] The first winding 201 and the second winding 202 on the primary side are wound side by side in the same layer and then four wire ends are pulled out for fixed connection to the four transformer pins respectively. The third winding 203 and the fourth winding 204 on the primary side are wound in the same layer and then four wire ends are pulled out for fixed connection to the four transformer pins respectively.

[0038] Alternatively, the first winding 201 and the second winding 202 on the primary side can be wound in parallel on the same layer and then four wire ends can be pulled out for fixed connection with four transformer pins respectively; the third winding 203 and the fourth winding on the primary side Group 204 is wound in the same layer and then four wire ends are pulled out to be fixedly connected to the four transformer pins respectively.

[0039] Alternatively, the first winding 201 and the second winding 202 on the primary side can be wound in parallel on the same layer and then four wire ends can be pulled out to be fixedly connected to the four transformer pins respectively; the third winding 203 and the fourth winding 204 on the primary side can be wound in parallel on the same layer and then four wire ends can be pulled out to be fixedly connected to the four transformer pins respectively.

[0040] Alternatively, the first winding 201 and the second winding 202 on the primary side are wound side-by-side in the same layer and then four wire ends are pulled out for fixed connection to the four transformer pins respectively. The third winding 203 and the fourth winding 204 on the primary side are wound in parallel in the same layer and then four wire ends are pulled out for fixed connection to the four transformer pins respectively.

[0041] Preferably, the secondary winding 210 includes a first winding N3 and a second winding N4. The first and second windings of the secondary winding are wound on the same layer and then two wire ends are pulled out for fixed connection to the pins of the two transformers respectively; or the first and second windings of the secondary winding are wound on the same layer in a split manner and then two wire ends are pulled out for fixed connection to the pins of the two transformers respectively.

[0042] Preferably, the first, second, third, and fourth windings of the primary side are made of triple-insulated wire, and the secondary winding is made of Litz wire; the frame is equipped with winding posts, which are designed to be taller, so as to make the effective window area coefficient of the transformer more reasonable when the winding structure of the primary and secondary sides is stacked.

[0043] Preferably, insulating tape 500 can be added between the primary and secondary windings to improve the insulation performance between the primary and secondary windings; a baffle 600 can be provided in the gaps next to the winding structure of the innermost winding, the secondary winding layer, and the third and fourth winding layers of the primary winding to fill the winding area of ​​the same layer so that the shielding layer can be wound more smoothly around it; a sleeve 700 can be added to the wires of the first, second, third, and fourth windings of the primary winding and / or the secondary winding; the frame is provided with a terminal block 102, and metal pins 103 extend from both sides of the terminal block for fixed connection with the winding wire ends of the transformer.

[0044] Based on the inventive concept, a vertical high-voltage transformer can also be designed, suitable for multi-winding transformer applications with multi-tube series flyback circuits. It includes a frame 100, multiple windings 200, and a magnetic core 300. The frame includes a winding post 101 and a through hole 104 opened in the middle of the winding post. Multiple windings are wound on the winding post of the frame. The magnetic core is inserted into the through hole of the frame. It also includes a copper foil layer, which is set between the primary winding and the secondary winding. Its first and last ends are not electrically connected, and it is provided with lead wires 401 for connecting to the ground through the lead wires. Multiple windings, including a first winding 201 and a second winding 202 on the primary side and a secondary winding 210, wherein the first winding on the primary side is wound on the bobbin winding post to form the innermost winding, and a first copper foil layer is wound on the innermost winding; the secondary winding is wound on the first copper foil layer; the second copper foil layer is wound on the secondary winding layer; and the second winding on the primary side is wound on the second copper foil layer.

[0045] Based on the inventive concept, a switching power supply can also be designed, including the vertical high-voltage transformer of this invention. The vertical high-voltage transformer is mounted on a PCB circuit board and, after product packaging, can be made into a switching power supply with a multi-transistor series flyback circuit topology of up to 350W. Its primary and secondary electrical isolation can reach 5000VAC, and it can meet the certification requirements of the national standard GB3836.4. In other embodiments, a switching power supply including the vertical high-voltage transformer of this invention can be designed. The transformer can be simplified to only the innermost winding, the inner second winding, and the first shielding layer between them. After product packaging, it can be made into a switching power supply of up to 350W. Thus, by improving the transformer structure, the overall performance of the power supply product, such as electrical isolation and noise, can be significantly improved to achieve the same or similar improvement effect, without limiting whether the primary and secondary electrical isolation of the switching power supply can reach 5000VAC, nor is it necessary to limit whether the switching power supply actually meets the certification requirements of the national standard GB3836.4.

[0046] Under the same flyback circuit topology application environment, the operation of the main power MOSFETs of a conventional transformer and the vertical high-voltage transformer of this invention were tested respectively. The stress peak (maximum value) of the obtained waveform is related to the input voltage and the leakage inductance of the transformer. Under the same input voltage and load, from Figure 9 and Figure 10 It can be seen that, Figure 9 The traditional transformer has a relatively large leakage inductance, with a stress peak of 536.06V; Figure 10 The leakage inductance of the vertical high-voltage transformer of this invention is relatively small, and the stress peak is 470.4V. Compared with the plateau voltage of 450V, this stress peak value is reduced from the traditional 85V peak voltage to 20V peak voltage, a reduction of more than 76%, which basically eliminates the stress peak caused by the transformer leakage inductance, and the optimization effect is obvious.

[0047] This invention relates to a vertical high-voltage transformer suitable for multi-tube series flyback topology switching power supplies up to 350W. By optimizing the winding structure and designing a suitable transformer frame, the primary and secondary electrical isolation of this type of transformer with added shielding can reach 5000VAC. Based on a more miniaturized product design, the increased transformer window area reduces the difficulty of winding processing, and the related temperature control can be comparable to or better than traditional transformers. Furthermore, because the spacing between the primary windings is closer, the transformer has lower leakage inductance and lower noise during withstand voltage testing, significantly improving the overall performance of the power supply product. It also meets the certification requirements of the national standard GB3836.4 for power supply products in coal mines, better meeting market demands compared to traditional transformers.

[0048] The above embodiments are merely illustrative of the present invention and are intended to help understand its methods and core concepts. For those skilled in the art, the above descriptions and examples will provide a clear understanding without departing from the principles of the present invention. Other equivalent applications that can be naturally associated with this invention, as well as various improvements and modifications made to this invention, all fall within the protection scope of the claims of this invention.

Claims

1. A vertical high-voltage transformer, suitable for multi-winding transformer applications with multi-tube series flyback circuits, comprising a frame, multiple windings, and a magnetic core. The frame includes winding posts and through holes in the middle of the winding posts. Multiple windings are wound on the winding posts of the frame, and the magnetic core is inserted into the through holes of the frame. The transformer is characterized in that: It also includes a shielding layer, which is set between the primary winding and the secondary winding. Its start and end ends are not electrically connected, and it is provided with lead wires for connecting to the ground. Multiple windings, including a primary winding, a second winding, a third winding, and a fourth winding, and a secondary winding. The primary windings, the first and second, are wound side-by-side in the same layer with four wire ends for fixed connection to four transformer pins. The primary windings, the third and fourth, are wound side-by-side in the same layer with four wire ends for fixed connection to four transformer pins. The secondary winding is wound in layers with two wire ends for fixed connection to two transformer pins. The primary windings, the first and second, are wound in the innermost layer, and the first shielding layer is wound on top of the primary windings. The secondary winding is wound on the first shielding layer. The second shielding layer is wound on the secondary winding layer. The primary windings, the third and fourth, are wound on the second shielding layer.

2. The vertical high-voltage transformer according to claim 1, characterized in that: The secondary winding includes a first winding and a second winding. The first and second windings of the secondary winding are wound on the same layer and then two wire ends are pulled out for fixed connection with the pins of the two transformers respectively.

3. The vertical high-voltage transformer according to claim 1, characterized in that: Insulating tape is added between the primary and secondary windings to improve the insulation performance between the primary and secondary windings; and / or a sleeve is added to the wire of one, several or all of the multiple windings.

4. The vertical high-voltage transformer according to claim 1, characterized in that: The first, second, third, and fourth windings of the primary side are made of triple-insulated wire, while the first and second windings of the secondary side are made of Litz wire.

5. The vertical high-voltage transformer according to claim 1, characterized in that: The shielding layer is made of copper foil; and / or the thickness of the shielding layer is determined by the primary current.

6. The vertical high-voltage transformer according to claim 1, characterized in that: The frame is equipped with winding posts, which are designed with increased height to achieve a more reasonable effective window area factor for the transformer in the miniaturized design of the primary and secondary side stacked winding structure. In the miniaturized design of the primary and secondary side stacked winding structure, a more reasonable effective window area factor can be determined based on the innermost layer size of the stacked winding structure. The innermost dimension of the group structure is the height of the two windings that are wound side by side with their wires and sides separated.

7. The vertical high-voltage transformer according to claim 1, characterized in that: The frame is provided with a terminal block, and metal pins extend from both sides of the terminal block for fixed connection with the winding ends of the transformer; and / or a baffle is provided in the gap next to the winding structure with multiple windings wound in the same layer, so as to fill the winding area in the same layer and facilitate the shielding layer to be wound more smoothly around it.

8. A vertical high-voltage transformer, suitable for multi-winding transformer applications with multi-tube series flyback circuits, comprising a frame, multiple windings, and a magnetic core. The frame includes winding posts and through holes in the middle of the winding posts. Multiple windings are wound on the winding posts of the frame, and the magnetic core is inserted into the through holes of the frame. The transformer is characterized in that: It also includes a copper foil layer, which is set between the primary winding and the secondary winding. Its start and end ends are not electrically connected, and it is provided with lead wires for connecting to the ground. Multiple windings, including the first, second, third, and fourth windings on the primary side and the secondary winding, wherein the first and second windings on the primary side are wound on the bobbin winding posts to form the innermost winding, and the first copper foil layer is wound on the innermost winding; the secondary winding is wound on the first copper foil layer; the second copper foil layer is wound on the secondary winding layer; and the third and fourth windings on the primary side are wound on the second copper foil layer.

9. The vertical high-voltage transformer according to claim 8, characterized in that: The first and second windings of the primary side are wound in parallel on the same layer and then four wire ends are pulled out to be fixedly connected to the four transformer pins respectively; or the first and second windings of the primary side are wound in parallel on the same layer and then four wire ends are pulled out to be fixedly connected to the four transformer pins respectively.

10. The vertical high-voltage transformer according to claim 8, characterized in that: The third and fourth windings on the primary side are wound in parallel on the same layer and then four wire ends are pulled out to be fixedly connected to the four transformer pins respectively; or the third and fourth windings on the primary side are wound in parallel on the same layer and then four wire ends are pulled out to be fixedly connected to the four transformer pins respectively.

11. The vertical high-voltage transformer according to claim 8, characterized in that: The secondary winding includes a first winding and a second winding. The first and second windings of the secondary winding are wound on the same layer and then two wire ends are pulled out for fixed connection with two transformer pins respectively; or the first and second windings of the secondary winding are wound side by side on the same layer in a split manner and then two wire ends are pulled out for fixed connection with two transformer pins respectively.

12. The vertical high-voltage transformer according to claim 8, characterized in that: The primary windings, including the first, second, third, and fourth windings, are made of triple-insulated wire, while the secondary winding is made of Litz wire. The quality; and / or the skeleton is provided with winding posts, and the winding posts are designed with increased height to make the effective window area factor of the transformer more reasonable when the winding structure of the primary and secondary sides is stacked.

13. The vertical high-voltage transformer according to claim 8, characterized in that: Insulating tape is added between the primary and secondary windings to improve the insulation performance between them; and / or baffles are provided in the gaps next to the winding structures of the innermost winding, the secondary winding layer, and the third and fourth winding layers of the primary winding to fill the winding area of ​​the same layer so that the shielding layer can be wound more smoothly around it; and / or sleeves are added to the wires of the first, second, third, and fourth windings of the primary winding and / or the secondary winding; and / or the frame is provided with terminal blocks, with metal pins extending from both sides of the terminal blocks for fixed connection with the winding wire ends of the transformer.

14. A vertical high-voltage transformer, suitable for multi-winding transformer applications with multi-tube series flyback circuits, comprising a frame, multiple windings, and a magnetic core, wherein the frame includes winding posts and through holes formed in the middle of the winding posts, multiple windings are wound on the winding posts of the frame, and the magnetic core is inserted into the through holes of the frame, characterized in that: It also includes a copper foil layer, which is set between the primary winding and the secondary winding. Its start and end ends are not electrically connected, and it is provided with lead wires for connecting to the ground. Multiple windings, including the primary winding (first and second windings) and the secondary winding, wherein, The first winding of the primary side is wound on the bobbin winding post to form the innermost winding, and the first copper foil layer is wound on the innermost winding; the secondary winding is wound on the first copper foil layer; the second copper foil layer is wound on the secondary winding layer; and the second winding of the primary side is wound on the second copper foil layer.

15. A high-voltage transformer frame, suitable for the vertical high-voltage transformer as described in any one of claims 1 to 14, comprising winding posts, characterized in that: The winding post adopts an increased height design to achieve a more reasonable effective window area factor for the transformer when designing a miniaturized winding structure with stacked primary and secondary sides.

16. The high-voltage transformer frame according to claim 15, characterized in that: The winding post of the frame is increased to about twice the height of the existing frame winding post; and / or the frame is provided with a terminal block, with metal pins extending from both sides of the terminal block for fixed connection with the winding wire end of the transformer.

17. A switching power supply, comprising a vertical high-voltage transformer as described in any one of claims 1 to 14, characterized in that, The vertical high-voltage transformer is mounted on a PCB circuit board and packaged into a switching power supply with a multi-tube series flyback circuit topology of up to 350W. Its primary and secondary electrical isolation can reach 5000VAC and can meet the certification requirements of the national standard GB3836.

4.

18. A switching power supply, comprising a vertical high-voltage transformer as described in any one of claims 1 to 14, characterized in that, The vertical high-voltage transformer is mounted on a PCB circuit board and packaged into a switching power supply of up to 350W, with primary and secondary electrical isolation up to 5000VAC.

19. A switching power supply, comprising a vertical high-voltage transformer as described in any one of claims 1 to 14, characterized in that, The vertical high-voltage transformer is mounted on a PCB circuit board and packaged into a switching power supply with a power consumption of up to 350W.

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