Network transformer

Abstract

The application relates to a network transformer and relates to the technical field of network signal transmission, and aims to solve the problem that the network transformer causes the leakage inductance to affect the signal transmission integrity due to the unwinding phenomenon of the winding in the initial coupling area of the signal line. The fourth winding and at least one first winding of the network transformer are twisted to form a first twisted wire group, the second winding and at least one third winding are twisted to form a second twisted wire group, and the second twisted wire group and the first twisted wire group are wound on the first magnetic ring with the same number of turns. The end of the first winding and the head of the third winding are twisted and form a first tap, and the end of the second winding and the head of the fourth winding are twisted and form a second tap. The head of the second winding and the end of the fourth winding are twisted on the outside of the first magnetic ring and form a third twisted wire group wound on a second magnetic ring. On the outside of the first magnetic ring, the head of the first winding and the end of the third winding are wound on the two ends of the first twisted wire group and the two ends of the second twisted wire group in opposite directions.

Description

Technical Field

[0001] This application relates to the field of network signal transmission technology, and in particular to a network transformer. Background Technology

[0002] In high-speed network equipment, the performance of the network transformer directly affects signal transmission quality. The leakage inductance problem at the initial coupling point of the signal line has remained unresolved. Although tapped crossovers can reduce leakage inductance at the taps, unavoidable unraveling of the windings in the initial coupling region prevents effective control of leakage inductance at this critical point. This leakage inductance significantly affects the integrity of high-frequency signal transmission and also negatively impacts the electromagnetic compatibility performance of the equipment. Utility Model Content

[0003] This application provides a network transformer to solve the problem that leakage inductance, which affects the integrity of signal transmission, occurs in the initial coupling region of the signal line due to the unavoidable scattering of the winding.

[0004] Some embodiments of this application provide a network transformer, including a first magnetic ring, a second magnetic ring, at least one first winding, at least one second winding, at least one third winding, and at least one fourth winding. The at least fourth winding and the at least one first winding are twisted together to form a first stranded group, which is wound around the first magnetic ring at least one turn. The at least one second winding and the at least one third winding are twisted together to form a second stranded group, which is wound around the first magnetic ring the same number of times as the first stranded group. The end of the first winding and the beginning of the third winding are twisted together on the outside of the first magnetic ring to form a first tap. The end of the second winding and the beginning of the fourth winding are twisted together on the outside of the first magnetic ring to form a second tap. The beginning of the second winding and the end of the fourth winding are twisted together on the outside of the first magnetic ring to form a third stranded group, which is wound around the second magnetic ring at least one turn. Specifically, on the outside of the first magnetic ring, the beginning of the first winding and the end of the third winding are wound in opposite directions around the ends of the first stranded group and the ends of the second stranded group.

[0005] Optionally, the number of first windings is at least two, and at least two first windings and a fourth winding are twisted together to form a first twisted group. The number of third windings is the same as the number of first windings, and at least two third windings are twisted together with a second winding to form a second twisted group.

[0006] Outside the first magnetic ring, at least two ends of the first winding and at least two beginnings of the third winding are twisted together to form a first tap, at least two beginnings of the first winding are twisted together to form a first wire bundle, and at least two ends of the third winding are twisted together to form a second wire bundle. The first wire bundle and the second wire bundle are wound around the ends of the first twisted wire group and the ends of the second twisted wire group in opposite directions.

[0007] Optionally, the first wire harness has a number of turns greater than or equal to 1 / 2 turn, the second wire harness has a number of turns greater than or equal to 1 / 2 turn, and the first and second wire harnesses have the same number of turns.

[0008] Optionally, the number of turns of the first and second wire harnesses is 1 / 2 turn.

[0009] Optionally, the first and second wire harnesses are wound with one turn.

[0010] Optionally, the number of turns of the first stranded wire group and the second stranded wire group around the first magnetic ring is 3-7.

[0011] Optionally, the first stranded wire is wound around an arc length region corresponding to a central angle of the first magnetic ring that is less than or equal to 240°.

[0012] Optionally, the third strand of wire is wound around the second magnetic ring 3-5 times.

[0013] Optionally, the second stranded wire is wound around the arc length region corresponding to the central angle of the second magnetic ring, which is less than or equal to 216°.

[0014] Optionally, the network transformer also includes a fifth winding, the beginning of which is twisted together with the end of the second winding and the beginning of the fourth winding to form a second tap, and the end of which is twisted together with the beginning of the second winding and the end of the fourth winding to form a third stranded wire group.

[0015] Optionally, the first and second stranded wire groups have the same degree of twist.

[0016] Optionally, in the first stranded wire group, the second stranded wire group, and the first tap, the twisting degree of the twisted pair structure is 26-34 strands per inch, the twisting degree of the twisted three structure is 16-24 strands per inch, and the twisting degree of the twisted four structure is 16-20 strands per inch.

[0017] Optionally, the twist rate of the second tap is 16-24 segments per inch.

[0018] Optionally, the twist rate of the third strand is 12-16 strands per inch.

[0019] Optionally, the end of the second tap is provided with a solder joint area with a length of less than or equal to 6 mm.

[0020] Optionally, the diameter of the first magnetic ring is larger than the diameter of the second magnetic ring.

[0021] Optionally, the radial thickness of the first magnetic ring is less than or equal to 5 mm.

[0022] Optionally, the gap between the first magnetic ring and the second magnetic ring is less than or equal to 2 mm.

[0023] The technical solutions provided in this application have the following advantages compared with the prior art:

[0024] In the network transformer provided in this embodiment, a first magnetic ring is wound synchronously with a first twisted wire group and a second twisted wire group, so that the magnetic fields generated by the first and second twisted wire groups at the first magnetic ring are superimposed, effectively improving the primary-secondary coupling efficiency. Specifically, the first and third windings, together with a first tap, form the primary coil, and the second and fourth windings, together with a second tap, form the secondary coil, thus forming the main structure of the network transformer. This couples the differential signal from the Ethernet chip of the external unit to the other end of the connecting network cable with different voltage levels through electromagnetic field conversion. Furthermore, the third twisted wire group wound on the second magnetic ring can act as a common-mode rejection coil. When a differential-mode signal passes through the common-mode rejection coil, opposite magnetic fields are generated in the second magnetic ring and cancel each other out, forming low impedance or near-zero impedance, allowing useful differential-mode signals to pass through almost without loss. When a common-mode signal passes through the common-mode rejection coil, the same magnetic field is generated in the second magnetic ring and amplified, thus superimposing and forming high impedance to suppress or absorb a large amount of common-mode interference signals, thereby achieving the effect of suppressing signal interference.

[0025] Reverse winding fixation refers to the use of opposite-direction winding between two cables to lock and secure the internal wire harness structure. Specifically, the reverse winding of the first and third windings fixes the ends of the first and second stranded wire groups close to the first magnetic ring, allowing the magnetic flux of the transformer structure to flow fully through the primary and secondary coils. This avoids voltage drop losses due to leakage inductance, which could affect the integrity of low-frequency and high-frequency signal transmission. In other words, by using reverse winding fixation, this application effectively reduces the leakage inductance intensity in the primary coupling region of the signal lines, thus reducing electromagnetic energy loss during high-frequency signal transmission. Simultaneously, the integrated reverse winding process reduces production steps, shortens the manufacturing cycle of high-frequency coils, and provides a more reliable electromagnetic conversion component for high-speed network equipment. Furthermore, the reverse winding layout allows the beginning of the first winding and the end of the third winding to form a symmetrical electromagnetic loop, resulting in uniform winding tension distribution and avoiding electromagnetic interference caused by loose local windings, thereby improving electromagnetic compatibility performance. Attached Figure Description

[0026] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0027] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0028] One or more embodiments are illustrated by way of example with reference numerals in the accompanying drawings. These illustrations do not constitute a limitation on the embodiments. Elements with the same reference numerals in the drawings are denoted as similar elements. Unless otherwise stated, the figures in the drawings are not to be limited by scale.

[0029] Figure 1 This is a schematic diagram of the structure of a network transformer in a related technical solution;

[0030] Figure 2 for Figure 1 The diagram shows an ideal connection of a network transformer.

[0031] Figure 3 for Figure 1 The diagram shows a practical connection of a network transformer.

[0032] Figure 4 for Figure 1 The diagram shows an equivalent circuit of the network transformer under actual operating conditions.

[0033] Figure 5 This application provides a partial structural schematic diagram of a network transformer according to some embodiments;

[0034] Figure 6 A schematic diagram of a network transformer in a wiring state provided in an embodiment of this application;

[0035] Figure 7 for Figure 6 The diagram shown is an equivalent circuit diagram of a network transformer.

[0036] Figure 8 for Figure 6 The diagram shows a winding structure of a network transformer.

[0037] Figure 9 for Figure 8 The diagram shows a noise reduction effect of a network transformer.

[0038] Explanation of reference numerals in the attached figures:

[0039] 1. First winding; 2. Second winding; 3. Third winding; 4. Fourth winding; 5. Fifth winding;

[0040] 10. First magnetic ring; 20. Second magnetic ring;

[0041] 31. First stranded wire group; 32. Second stranded wire group; 33. Third stranded wire group;

[0042] 41. First tap; 42. Second tap;

[0043] 51. First wire harness; 52. Second wire harness. Detailed Implementation

[0044] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0045] The following provides numerous different embodiments or examples for implementing various structures of this application. Components and arrangements of specific examples are described below. Of course, these are merely examples and are not intended to limit the scope of this application. Furthermore, reference numerals and / or letters may be repeated in different examples. Such repetition is for simplicity and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed.

[0046] For ease of description, spatial relative terms may be used in the text to describe the relative position or movement of one element or feature relative to another element or feature, as shown in the figure. These relative terms include, for example, "inside," "outside," "middle," "outer," "below," "below," "above," "front," "back," etc. Such spatial relative terms are intended to include different orientations of the device in use or operation, other than those depicted in the figure. For example, if the device in the figure undergoes a positional flip, orientation change, or change of motion, these directional indications will change accordingly. For instance, an element described as "below other elements or features" or "below other elements or features" will subsequently be oriented "above other elements or features" or "above other elements or features." Therefore, the example term "below" can include both upper and lower orientations. The device may be otherwise oriented (rotated 90 degrees or in other directions), and the spatial relative descriptors used in the text will be interpreted accordingly.

[0047] In high-speed network equipment, the performance of the network transformer directly affects signal transmission quality. The leakage inductance problem at the primary coupling point of the signal line has remained unresolved. Although tapped crossovers can reduce leakage inductance at the taps, unavoidable unraveling of the windings in the primary coupling area prevents effective control of leakage inductance at this critical point. This leakage inductance significantly affects the integrity of high-frequency signal transmission and also negatively impacts the electromagnetic compatibility performance of the equipment.

[0048] For example, such as Figure 1 Show, Figure 1 This is a schematic diagram of a network transformer in a related technical solution. The signal lines T1, T2, and T5, and the tap lines T3 and T4 are wound sequentially around the transformer's magnetic coil. For example, signal line T1 can be one end of two blue cables, signal line T2 can be one end of two yellow cables, tap line T3 can be the other end of two blue cables and two yellow cables, tap line T4 can be one end of three cables (red, blue, and gold), signal line T5 can be the other end of a gold cable, signal line T6 can be the other end of a blue cable, and signal line T7 can be the other end of the three gold cables.

[0049] Based on this, refer to Figure 2 , Figure 2 for Figure 1 The diagram shows an ideal connection of a network transformer. In an ideal state, the magnetic flux in the transformer coils flows uniformly through the primary coils T5, T4, and T6, and the secondary coils T1, T3, and T2, so that there is little or no line loss during signal transmission.

[0050] However, in practical applications, the taps and signal lines cannot be fully coupled at the outer radial side of the transformer's magnetic coil. (Refer to...) Figure 3 , Figure 3 for Figure 1 The diagram shows a practical connection of a network transformer. This design prevents the magnetic flux in the transformer coil from completely passing through the secondary winding during actual operation, thus generating leakage inductances A1 and A2 in the secondary coil.

[0051] However, the equivalent circuit of a real network transformer will increase line losses due to the presence of leakage inductance, such as... Figure 4 As shown, Figure 4 for Figure 1 The diagram shows an equivalent circuit of the network transformer under actual operating conditions. The input load (IN) of the primary coil is V. in The output load of the secondary coil is:

[0052] V in -2×π·f·Lk×2.

[0053] As shown above, the output load of the secondary coil is inversely proportional to the leakage inductance Lk and the signal frequency f. Especially for high-frequency signals, such as network signals above 2.5G or 10G, the presence of leakage inductance Lk will cause a significant reduction in the output voltage of the secondary coil under high-frequency signals, thereby affecting the transmission integrity of high-frequency signals.

[0054] Based on this, please refer to Figures 5 to 9 This application provides a network transformer to solve the problem that leakage inductance, which affects signal transmission integrity, will inevitably occur in the initial coupling area of ​​the signal line due to the unavoidable scattering of the winding.

[0055] like Figure 5 and Figure 6 As shown, the network transformer includes a first magnetic ring 10, a second magnetic ring 20, at least one first winding 1, at least one second winding 2, at least one third winding 3, and at least one fourth winding 4. The at least one fourth winding 4 and the at least one first winding 1 are twisted together to form a first stranded group 31, which is wound around the first magnetic ring 10 at least one turn. The at least one second winding 2 and the at least one third winding 3 are twisted together to form a second stranded group 32, which is wound around the first magnetic ring 10 the same number of times as the first stranded group 31.

[0056] The first stranded wire group 31 and the second stranded wire group 32 are wound synchronously on the first magnetic ring 10. That is, the first stranded wire group 31 and the second stranded wire group 32 are wound one, two, three or more times on the first magnetic ring 10.

[0057] The first stranded wire group 31 refers to a wire bundle formed by at least one fourth winding 4 and at least one first winding 1 in a helical twisting manner. Specifically, it can be implemented using a double-wire or triple-wire twisting structure, reducing the winding gap through tight twisting. The second stranded wire group 32 refers to a wire bundle formed by at least one second winding 2 and at least one third winding 3 in the same twisting manner. It maintains a synchronous winding path with the first stranded wire group 31 to ensure the symmetry of magnetic field coupling.

[0058] Reference Figure 5 The side of the first magnetic ring 10 shown along the axial direction is the front side, and the four or six windings located on the front side of the first magnetic ring 10 are its starting ends (such as the inlet end). Correspondingly, the side of the first magnetic ring 10 facing away along the axial direction is the back side, and the four or six windings located on the back side of the first magnetic ring 10 are its ending ends (such as the outlet end).

[0059] In this configuration, the number of cables in the first twisted wire group 31 and the second twisted wire group 32 is the same, meaning the number of cables in the first winding 1 and the third winding 3 is the same. Taking a case where the number of first winding 1 and third winding 3 is one, then the first twisted wire group 31 and the second twisted wire group 32 are twisted-pair structures. If the number of first winding 1 and third winding 3 is two, then both the first twisted wire group 31 and the second twisted wire group 32 are three-twisted structures. If the number of first winding 1 and third winding 3 is three, then both the first twisted wire group 31 and the second twisted wire group 32 are four-twisted structures, and so on.

[0060] Continue to refer to Figure 5 and Figure 6 The end of the first winding 1 and the beginning of the third winding 3 are twisted together on the outside of the first magnetic ring 10 to form a first tap 41. This outside can be the side of the first magnetic ring 10 that is radially away from the center. The beginning of the second winding 2 and the end of the fourth winding 4 are twisted together on the outside of the first magnetic ring 10 to form a second tap 42.

[0061] The first tap 41 refers to the electrical connection bundle formed by twisting the end of the first winding 1 and the beginning of the third winding 3 on the outer side of the first magnetic ring 10, thus preventing the windings from unraveling by fixing the twisting position. The second tap 42 refers to the electrical connection node formed at a specific position on the outer side of the first magnetic ring 10 after the two windings, the end of the second winding 2 and the beginning of the fourth winding 4, are twisted together, so that the current path forms a closed loop on the surface of the magnetic ring. The first tap 41 and the second tap 42 form a fixed connection point on the outer side of the first magnetic ring 10, so that the current flows along a predetermined path and prevents the windings from shifting position on the surface of the first magnetic ring 10.

[0062] In other words, when the number of first winding 1 and third winding 3 is one, the second tap 42 is a twisted pair structure. When the number of first winding 1 and third winding 3 is two, the second tap 42 is a four-twisted structure. When the number of first winding 1 and third winding 3 is three, the second tap 42 is a six-twisted structure, meaning the number of first winding 1 and third winding 3 is the same, and so on.

[0063] Correspondingly, the number of second windings 2 and fourth windings 4 can be one, two, or more, and there is no limitation thereto. Unless otherwise specified, this application embodiment uses one number of second windings 2 and fourth windings 4 as an example.

[0064] It should be noted that, in this embodiment, for the first winding 1, the second winding 2, the third winding 3, and the fourth winding 4, taking the input side of the first winding 1 when winding the first magnetic ring 10 as the starting end as an example, the output side of the first winding 1 when winding the first magnetic ring 10 is the ending end. Correspondingly, the fourth winding 4, which is hinged to the starting end of the first winding 1 at the same end, is also the starting end, and the other end is the ending end. Similarly, since the first stranded wire group 31 and the second stranded wire group 32 are wound synchronously, the input side of the second stranded wire group 32 and the input side of the first stranded wire group 31 are located on the same side of the first magnetic ring 10 along the axial direction, that is, the second winding 2 and the third winding 3 on the input side of the second stranded wire group 32 are also the starting ends.

[0065] like Figure 6 and Figure 8 As shown, the end of the second winding 2 and the beginning of the fourth winding 4 are twisted together on the outside of the first magnetic ring 10 to form a third twisted wire group 33, which is wound around the second magnetic ring 20 at least once. Specifically, on the outside of the first magnetic ring 10, the beginning of the first winding 1 and the end of the third winding 3 are wound in opposite directions around the two ends of the first twisted wire group 31 and the two ends of the second twisted wire group 32. The third twisted wire group 33 refers to an independent wire bundle formed by twisting the end of the second winding 2 and the beginning of the fourth winding 4, which forms a secondary coupling circuit around the second magnetic ring 20.

[0066] Based on this, the network transformer provided in this application embodiment uses a first twisted wire group 31 and a second twisted wire group 32 to simultaneously wind a first magnetic ring 10, so that the magnetic fields generated by the first twisted wire group 31 and the second twisted wire group 32 at the first magnetic ring 10 are superimposed, effectively improving the primary-secondary coupling efficiency. Specifically, the first winding 1 and the third winding 3, together with the first tap 41, form the primary coil, and the second winding 2 and the fourth winding 4, together with the second tap 42, form the secondary coil, thus forming the main structure of the network transformer. This couples the differential signal from the Ethernet chip of the external unit to the other end of the connecting network cable with different voltage levels through electromagnetic field conversion. Furthermore, the third twisted wire group 33 wound on the second magnetic ring 20 can serve as a common-mode rejection coil. When a differential-mode signal passes through the common-mode rejection coil, opposite magnetic fields are generated in the second magnetic ring 20 and cancel each other out, forming low impedance or approximately no impedance, allowing useful differential-mode signals to pass through almost without loss. When a common-mode signal passes through the common-mode suppression coil, it will generate the same magnetic field in the second magnetic ring 20 and be strengthened, thereby superimposing and forming a high impedance to suppress or absorb a large amount of common-mode interference signals, thus achieving the effect of suppressing signal interference.

[0067] Reverse winding fixation refers to the use of reverse winding between two cables (or wire harnesses) to lock and secure the internal wire harness structure. Specifically, by reverse winding the first winding 1 and the third winding 3, the ends of the first twisted wire group 31 and the second twisted wire group 32 are fixed and positioned close to the first magnetic ring 10. This allows the magnetic flux of the transformer structure to flow fully through the primary and secondary coils, thereby avoiding voltage drop losses due to leakage inductance that could affect the integrity of low-frequency and high-frequency signal transmission. In other words, through reverse winding fixation, this application effectively reduces the leakage inductance intensity in the primary coupling region of the signal line, reducing electromagnetic energy loss during high-frequency signal transmission. Simultaneously, the integrated reverse winding process reduces production steps, shortens the manufacturing cycle of the high-frequency coil, and provides a more reliable electromagnetic conversion component for high-speed network equipment. Furthermore, the reverse winding layout allows the beginning of the first winding 1 and the end of the third winding 3 to form a symmetrical electromagnetic circuit, resulting in uniform winding tension distribution and avoiding electromagnetic interference caused by localized loose winding, thus improving electromagnetic compatibility performance.

[0068] In some embodiments, such as Figure 5 As shown, the number of first windings 1 is at least two, and at least two first windings 1 and fourth windings 4 are twisted together to form a first twisted wire group 31. The number of third windings 3 is the same as the number of first windings 1, and at least two third windings 3 are twisted together with second windings 2 to form a second twisted wire group 32.

[0069] like Figure 6 and Figure 8 As shown, on the outside of the first magnetic ring 10, the ends of at least two first windings 1 and the beginnings of at least two third windings 3 are twisted together to form a first tap 41. The beginnings of at least two first windings 1 are twisted together to form a first wire bundle 51. The ends of at least two third windings 3 are twisted together to form a second wire bundle 52. The first wire bundle 51 and the second wire bundle 52 are wound in opposite directions around the two ends of the first twisted wire group 31 and the two ends of the second twisted wire group 32.

[0070] Since there are at least two first windings 1 and two third windings 3, let's take an example where there are two first windings 1 and two third windings 3. The ends of the two first windings 1 and the beginnings of the two third windings 3 are twisted together to form the first tap 41 of the four-twisted wire. The beginnings of the two first windings 1 are twisted together to form the first bundle 51 of the twisted pair. The ends of the two third windings 3 are twisted together to form the second bundle 52 of the twisted pair.

[0071] Subsequently, the first wire bundle 51 can be wound clockwise around the two ends of the first twisted wire group 31, and the second wire bundle 52 can be wound counterclockwise around the two ends of the second twisted wire group 32. This fixes the first twisted wire group 31 and the second twisted wire group 32 close to the first magnetic ring 10, allowing the magnetic flux of the transformer structure to flow fully through the primary and secondary coils, thereby avoiding voltage drop losses caused by leakage inductance that could affect the integrity of low-frequency and high-frequency signal transmission. Furthermore, the electromagnetic fields generated by the counter-symmetrically wound first wire bundle 51 and second wire bundle 52 can cancel each other out (e.g., canceling parasitic inductance), further balancing the electromagnetic field distribution to prevent the unidirectional winding structure from causing excessive concentration of the magnetic field in a specific direction, thus reducing signal transmission quality. Simultaneously, the twisted structure of multiple wires reduces the dispersed arrangement of individual wires on the surface of the magnetic ring, avoiding increased local leakage inductance due to unraveling of the windings.

[0072] Combination Figure 7 and Figure 8 The first wire harness 51 and the second wire harness 52, together with the first tap 41, form the primary coil. The second winding 2 and the fourth winding 4, together with the second tap 42, form the secondary coil, thus forming the main structure of the network transformer. This couples the differential signal from the Ethernet chip of the external unit to the other end of the connecting network cable with different voltage levels through electromagnetic field conversion. Furthermore, the third twisted wire group 33 wound on the second magnetic ring 20 can serve as a common-mode rejection coil. When a differential-mode signal passes through the common-mode rejection coil, opposite magnetic fields are generated in the second magnetic ring 20 and cancel each other out, forming a low impedance or approximately zero impedance, allowing useful differential-mode signals to pass through almost without loss. When a common-mode signal passes through the common-mode rejection coil, the same magnetic field is generated in the second magnetic ring 20 and amplified, thus superimposing and forming a high impedance to suppress or absorb a large amount of common-mode interference signals, thereby achieving the effect of suppressing signal interference.

[0073] The above solution effectively reduces the leakage inductance in the primary-secondary coupling region, improving the integrity of high-frequency signal transmission. The multi-strand twisted structure ensures uniform coverage of the first twisted wire group 31 and the second twisted wire group 32 on the surface of the first magnetic ring 10, preventing sudden changes in leakage inductance in localized areas due to wire dispersion. The reverse winding design of the first wire bundle 51 and the second wire bundle 52 reduces the contact distance between the first twisted wire group 31 and the second twisted wire group 32 and the first magnetic ring 10, while also balancing the electromagnetic field distribution at the winding point. This prevents the unidirectional winding structure from causing excessive magnetic field concentration in a specific direction, which would reduce signal transmission quality. Simultaneously, the centralized processing of the wire bundles and tap structures reduces welding steps in the production process. For example, what previously required eight end treatments for four wires can now be completed in only two treatments with two sets of wire bundles, significantly improving manufacturing efficiency.

[0074] Specifically, the first wire harness 51 has at least 1 / 2 turn, and the second wire harness 52 has at least 1 / 2 turn, with the first wire harness 51 and the second wire harness 52 having the same number of turns. The same number of turns means that the distribution density and path of the first wire harness 51 and the second wire harness 52 at the coil are symmetrical, thereby ensuring a uniform distribution of magnetic flux near the first magnetic ring 10.

[0075] The number of turns of the first wire harness 51 and the second wire harness 52 can be an integer multiple of 1 / 2 turn. Correspondingly, when the number of the first winding 1 and the third winding 3 is one, the number of turns of the beginning of the first winding 1 and the end of the third winding 3 are also an integer multiple of 1 / 2 turn.

[0076] Taking the first wire harness 51 as an example, the first wire harness 51 is wound around the ends of the first stranded wire group 31 and the second stranded wire group 32 by 180°, which is 1 / 2 turn. The first wire harness 51 is wound around the ends of the first stranded wire group 31 and the second stranded wire group 32 by 360°, which is 1 turn.

[0077] The first wire harness 51 and the second wire harness 52 can be flexibly adjusted in terms of winding direction and number of turns as needed. It is only necessary to ensure that the first wire harness 51 and the second wire harness 52 have the same number of turns and opposite winding directions. There are no restrictions on this.

[0078] Specifically, when the first wire bundle 51 and the second wire bundle 52 are wound with the same number of turns, the two wire bundles (a single first winding 1 and a single third winding 3 are simultaneously wound) form symmetrical current loops at both ends of the first twisted wire group 31 and the second twisted wire group 32, making the magnetic field distribution tend to be balanced. Furthermore, the winding fixation avoids a decrease in magnetic coupling efficiency in local areas due to loose winding. This scheme, through a symmetrical winding design, enables the magnetic fields of the two sets of windings to compensate for each other. Simultaneously, by limiting the minimum number of winding turns, it ensures tight contact between the winding and the magnetic ring, avoiding parasitic capacitance effects caused by loose winding during high-frequency signal transmission.

[0079] Through the above technical solution, this application effectively reduces the leakage inductance in the primary coupling region, improves the integrity of signal transmission, simplifies the winding process, and makes the winding distribution more uniform and controllable, thereby improving the production efficiency and product consistency of high-frequency network transformers.

[0080] For example, the first wire harness 51 is wound clockwise around the first twisted wire group 31 and the second twisted wire group 32 by half a turn, and the second wire harness 52 is wound counterclockwise around the first twisted wire group 31 and the second twisted wire group 32 by half a turn. Alternatively, the winding direction of the first wire harness 51 and the second wire harness 52 can be reversed without changing the number of turns. This is to avoid the unidirectional winding structure causing excessive concentration of the magnetic field in a specific direction, which would reduce the signal transmission quality. The minimum 1 / 2 turn winding requirement ensures that the first wire harness 51 and the second wire harness 52 have sufficient winding coverage length outside the magnetic ring, avoiding the loosening of the first twisted wire group 31 and the second twisted wire group 32 due to insufficient winding in conventional processes, thereby avoiding voltage drop losses caused by leakage inductance that would affect the integrity of low-frequency and high-frequency signal transmission.

[0081] Alternatively, the first wire harness 51 may be wound clockwise around the first twisted wire group 31 and the second twisted wire group 32 once, and the second wire harness 52 may be wound counterclockwise around the first twisted wire group 31 and the second twisted wire group 32 once. The winding directions of the first wire harness 51 and the second wire harness 52 can also be reversed without changing the number of turns. This is to avoid the unidirectional winding structure causing excessive concentration of the magnetic field in a specific direction, which would reduce signal transmission quality. Furthermore, the requirement of one turn each for the first wire harness 51 and the second wire harness 52 ensures that the first wire harness 51 and the second wire harness 52 have sufficient winding coverage length outside the magnetic ring, avoiding the loosening of the first twisted wire group 31 and the second twisted wire group 32 due to insufficient winding in conventional processes. This avoids voltage drop losses caused by leakage inductance that could affect the integrity of low-frequency and high-frequency signal transmission.

[0082] In some embodiments, such as Figure 6 and Figure 8 As shown, the network transformer also includes a fifth winding 5, the beginning of the fifth winding 5 is twisted together with the end of the second winding 2 and the beginning of the fourth winding 4 to form a second tap 42, and the end of the fifth winding 5 is twisted together with the beginning of the second winding 2 and the end of the fourth winding 4 to form a third stranded wire group 33.

[0083] The fifth winding 5 refers to the additional conductor connecting the second tap 42 and the third stranded wire group 33. It can be made of the same enameled wire or insulated wire as the first winding 1, to enhance the mechanical stability between the windings through twisting. Twisting refers to multiple conductors being wound in a spiral to form a combined conductor, which can be achieved using a three-strand twisting process. This reduces leakage inductance caused by loose windings through physical contact.

[0084] By introducing a fifth winding 5, the beginning and end ends of both the second winding 2 and the fourth winding 4 are twisted together with the fifth winding 5, forming a stable three-twisted wire bundle structure. The windings remain twisted throughout the magnetic ring winding process, avoiding a decrease in electromagnetic coupling efficiency due to dispersion. Furthermore, the introduction of the fifth winding 5 reduces the number of steps required to separately process the second winding 2 and the fourth winding 4, simplifying the production process.

[0085] In some embodiments, such as 5 and Figure 6 As shown, the first stranded wire group 31 and the second stranded wire group 32 are wound around the first magnetic ring 10 two, three, or more times. For example, the number of turns of the first stranded wire group 31 and the second stranded wire group 32 can be set to 3-7 turns.

[0086] Specifically, at the first magnetic ring 10, the more turns the first twisted wire group 31 and the second twisted wire group 32 have, the better the response and common-mode rejection capability, and the better the EMI (Electromagnetic Interference) performance, i.e., the better the anti-interference capability. Conversely, the fewer turns the first twisted wire group 31 and the second twisted wire group 32 have, the more suitable they are for high-speed signal transmission, with lower insertion loss and higher density, which is beneficial for overall miniaturization design.

[0087] If the number of turns of the first twisted wire group 31 and the second twisted wire group 32 around the first magnetic ring 10 is less than 3, the anti-interference performance will be poor. If the number of turns of the first twisted wire group 31 and the second twisted wire group 32 around the first magnetic ring 10 is greater than 7, the structure will be complex and unsuitable for high-speed network signal transmission. Therefore, the number of turns of the first twisted wire group 31 and the second twisted wire group 32 around the first magnetic ring 10 can be set to 3, 4, 5, 6, or 7. For example, taking a network transformer suitable for 2.5G, 10G, or higher network modules as an example, the number of turns of the first twisted wire group 31 and the second twisted wire group 32 around the first magnetic ring 10 can be set to seven to ensure good anti-interference capability of network signals during high-speed transmission and guarantee the integrity of high-speed network signal transmission.

[0088] Correspondingly, such as Figure 5 and Figure 6 As shown, at the first magnetic ring 10, the first stranded wire group 31 and the second stranded wire group 32 are wound within an arc-length region of the first magnetic ring 10 with a central angle less than or equal to 240°. The first stranded wire group 31 and the second stranded wire group 32 are evenly distributed circumferentially within the aforementioned arc-length region of the first magnetic ring 10.

[0089] By confining the first strand group 31 and the second strand group 32 to an arc length region with a corresponding central angle of 240°, the two strand structures of the first strand group 31 and the second strand group 32 are symmetrically distributed at a specific angle on the surface of the first magnetic ring 10. This maintains the stability of the winding structure and prevents excessive dispersion of the two strands in the unwound areas. This winding method, through the coordinated control of the number of turns and the coverage angle, ensures that the first strand group 31 and the second strand group 32 are uniformly and tightly arranged on the surface of the first magnetic ring 10. While ensuring the symmetry of the winding, the corresponding areas with at least 120° central angles provide operational space for the connection of taps, wire harnesses, and reverse symmetrical winding structures.

[0090] In some embodiments, such as Figure 6 and Figure 8 As shown, at the second magnetic ring 20, the third stranded wire group 33 is wound around the second magnetic ring 20 two, three, or more times. For example, the third stranded wire group 33 is wound around the second magnetic ring 20 3-5 times.

[0091] The third stranded wire group 33, wound on the second magnetic ring 20, is mainly used as a common-mode rejection coil to suppress signal interference by suppressing or absorbing a large amount of common-mode interference signals. The more turns the third stranded wire group 33 has, the better its response and common-mode rejection capability, thus improving EMI (Electromagnetic Interference) performance and providing better anti-interference capability. Conversely, fewer turns in the third stranded wire group 33 are more suitable for high-speed signal transmission, resulting in lower insertion loss and higher density, which is beneficial for overall miniaturization design.

[0092] Therefore, if the number of turns of the third twisted wire group 33 wound around the second magnetic ring 20 is less than three, it will result in poor anti-interference performance. If the number of turns of the third twisted wire group 33 wound around the second magnetic ring 20 is more than five, it will result in a complex structure that is not suitable for the transmission of high-speed network signals. That is, the number of turns of the third twisted wire group 33 wound around the second magnetic ring 20 can be set to 3, 4, or 5. For example, taking a network transformer suitable for 2.5G, 10G, or higher network modules as an example, the number of turns of the third twisted wire group 33 wound around the second magnetic ring 20 can be set to five, which maintains good anti-interference capability while being more suitable for the transmission of high-speed network signals.

[0093] It should be noted that if there is no need to transmit high-speed network signals, the number of turns at the first magnetic ring 10 and the second magnetic ring 20 can be set to one or two turns, resulting in a simple structure.

[0094] Correspondingly, such as Figure 6 and Figure 8As shown, at the second magnetic ring 20, the third stranded wire group 33 is wound within an arc-length region of the second magnetic ring 20 with a central angle less than or equal to 216°. The third stranded wire group 33 is uniformly distributed circumferentially along the second magnetic ring 20 within the aforementioned arc-length region.

[0095] By limiting the winding of the third stranded wire group 33 to an arc length region corresponding to a central angle of 216°, the conductors of the third stranded wire group 33 are symmetrically distributed at a specific angle on the surface of the second magnetic ring 20. This maintains the stability of the winding structure and prevents excessive dispersion of the conductors in the unstretched areas. Through the coordinated control of the number of turns and the coverage angle, this winding method ensures that the windings of the third stranded wire group 33 form a uniform and compact arrangement on the surface of the second magnetic ring 20. While ensuring winding symmetry, the corresponding areas at other central angles of 144° provide operational space for tap connections. This improves the utilization efficiency of the material of the second magnetic ring 20 and reduces leakage inductance caused by uneven winding distribution.

[0096] It should be noted that at the first magnetic ring 10 and the second magnetic ring 20, as the number of turns increases, the winding coverage area of ​​the coil can be increased accordingly, that is, the arc length area corresponding to the central angle can be increased. For example, at the first magnetic ring 10, the arc length covered by the first stranded wire group 31 and the second stranded wire group 32 after seven turns can correspond to a central angle of 240°. At the second magnetic ring 20, the arc length covered by the third stranded wire group 33 after five turns can correspond to a central angle of 216°.

[0097] In this design, the first stranded wire group 31 and the second stranded wire group 32 have the same degree of twist. The degree of twist refers to the number of spiral twists of the stranded wire pair per unit length, which can be achieved by mechanically twisting the winding using a stranding machine. By setting the first stranded wire group 31 and the second stranded wire group 32 to use the same degree of twist, and by winding the first stranded wire group 31 and the second stranded wire group 32 on the first magnetic ring 10 with the same number of turns or by winding them synchronously, the distribution characteristics of the windings on the magnetic ring 10 are kept uniform, thereby effectively controlling the leakage inductance in the initial coupling region.

[0098] For example, in the first stranded wire group 31, the second stranded wire group 32 and the first tap 41, the twisting degree of the twisted pair structure is 26-34 strands per inch, the twisting degree of the three-strand structure is 16-24 strands per inch, and the twisting degree of the four-strand structure is 16-20 strands per inch.

[0099] Taking the first stranded wire group 31, the second stranded wire group 32, and the first tap as examples, where the first winding 1 and the third winding 3 are all one, the twisting degree of the first stranded wire group 31, the second stranded wire group 32, and the first tap 41 is 26-34 strands per inch.

[0100] For example, the twist rate per inch of the first strand group 31, the second strand group 32, and the first tap 41 can be set to 27, 28, 29, 30, 31, 32, 33, or 34 strands. This can be flexibly set according to actual production arrangements and performance requirements, and there are no limitations on this.

[0101] Alternatively, if there are two first windings 1 and two third windings 3. The first twisted wire group 31 and the second twisted wire group 32 are three-twisted wire structures, with a twist rate of 16-24 sections per inch. The first tap 41 is a four-twisted wire structure, with a twist rate of 16-20 sections per inch. The first wire bundle 51 and the second wire bundle 52 are two-twisted wire structures, with a twist rate of 26-34 sections per inch.

[0102] For example, the twist density of the first strand group 31 and the second strand group 32 can be set to 16, 17, 18, 19, 20, 21, 22, 23, or 24 strands per inch. The first strand group 31 and the second strand group 32 balance the electromagnetic coupling efficiency and structural stability between the windings by controlling the twist density. By setting the twist density of the first strand group 30 to 16-24 strands per inch, the winding can maintain a tight twist to enhance magnetic flux coupling, while avoiding stress concentration and excessive wire usage caused by excessive twisting.

[0103] Correspondingly, the twist rate of the first tap 41 can be set to 16, 17, 18, 19, or 20 strands per inch. Thus, when the first tap 41 of the four-stranded cable structure uses a twist rate of 17-20 strands per inch, it ensures the mechanical strength of the tap area while avoiding high-frequency losses and wire losses caused by excessive twisting, and ensures that the tap area has stable electrical connection characteristics before the solder joint is formed.

[0104] When there are two first windings 1 and two third windings 3, the beginning ends of the two first windings 1 are twisted together to form a first twisted pair wire bundle 51, and the ends of the two third windings 3 are twisted together to form a second twisted pair wire bundle 52. The twisting degree of the first wire bundle 51 and the second wire bundle 52 is the same, and this twisting degree can be set to 27, 28, 29, 30, 31, 32, 33, or 34 sections. That is, by setting a higher twisting degree for the first wire bundle 51 and the second wire bundle 52, the wire unraveling is suppressed, thereby maintaining the structural stability of the wire bundle.

[0105] Since the second tap 42 serves as both a partial tap structure and a connecting segment structure for the third stranded wire group 33, when the second tap 42 includes the fifth winding 5, the twist rate of the second tap 42 can be set to 16-24 sections per inch, specifically 16, 17, 18, 19, 20, 21, 22, 23, or 24 sections. That is, the twist rate of the second tap 42 can be set between that of the first tap 41 and the first stranded wire group 31.

[0106] Correspondingly, the twist rate of the third strand group 33 can be set to 12-16 strands per inch, specifically 12, 13, 14, 15, or 16 strands. That is, the low twist rate design of the third strand group 33 allows for appropriate gaps to be maintained when the winding is wound on the second magnetic ring 20, for example, by using a single-axis stranding device to reduce stranding tension, thereby reducing the springback phenomenon of the winding after the magnetic ring is fixed.

[0107] This solution uses differentiated stranding settings in different regions to maintain a tight stranding at critical contact points, while reducing the deformation risk of the first strand group 31, the second strand group 32, and the third strand group 33 during the magnetic ring winding process. This zoned control of stranding simplifies the manufacturing process of high-frequency coils; for example, stable electrical connections can be achieved at the taps without additional reinforcement, thereby improving production efficiency and product consistency.

[0108] In some embodiments, the end of the second tap 42 may be provided with a solder joint area with a length of less than or equal to 6 mm.

[0109] The solder joint area refers to the area at the end of the wire where the insulation layer has been removed and tinned. This can be achieved by using a hot air gun for local heating combined with flux wetting. This area is used to ensure a reliable connection between the solder joint and the external circuit.

[0110] By providing a solder joint area of ​​up to 6 mm at the end of the second tap 42 and pre-treating the wire ends to form a metallized surface, subsequent soldering processes do not require additional insulation stripping. This structural design maintains electrical connection reliability while avoiding the risk of wire damage caused by manual wire stripping in traditional processes. Furthermore, it allows for a more compact spatial distribution of the exposed conductors after stranding at the second tap 42, effectively suppressing electromagnetic field leakage caused by excessive conductor spacing during high-frequency signal transmission, thereby improving high-frequency signal transmission characteristics.

[0111] In some embodiments, the diameter of the first magnetic ring 10 is larger than the diameter of the second magnetic ring 20. When the diameter of the first magnetic ring 10 is larger than the diameter of the second magnetic ring 20, the magnetic field distribution area of ​​the primary and secondary windings is expanded, thereby controlling the winding spacing at the primary coupling of the signal lines and avoiding an increase in leakage inductance due to the windings spreading out.

[0112] The radial thickness of the first magnetic ring 10 is less than or equal to 5 mm. The radial thickness of the first magnetic ring 10 refers to the radial distance between the inner and outer circles in the cross-section of the magnetic ring. Specifically, a thin-walled structure design can be adopted to reduce material usage. By controlling the radial thickness of the first magnetic ring 10 to be less than 5 mm, the matching degree between the magnetic ring volume and the winding path is improved, which is beneficial for the winding to fit tightly against the surface of the magnetic ring. This optimizes the distribution of the winding on the magnetic ring, thereby reducing energy loss during high-frequency signal transmission.

[0113] The gap between the first magnetic ring 10 and the second magnetic ring 20 being less than or equal to 2 mm refers to the physical spacing limit between the two magnetic rings, that is, the minimum radial distance between the first magnetic ring 10 and the second magnetic ring 20. Specifically, the spacing can be controlled through positioning fixtures or winding processes, such as using insulating pads or injection molding structures to fix the position of the magnetic rings. This spacing limit can suppress edge effects during magnetic field coupling and reduce the impact of leakage inductance on signal integrity.

[0114] In the actual assembly process, the first winding 1, the second winding 2, the third winding 3, and the fourth winding 4 can be set to red, yellow, green, and blue enameled or coated wires, respectively, to facilitate the identification of wire winding and connection during assembly. Correspondingly, the fifth winding 5 can also be set to red enameled or red coated wire, without limitation.

[0115] The above scheme allows for configuration such as Figure 8 The network transformer shown is illustrated. Performance tests were conducted on the network transformers before and after the improvement to test the return loss parameters of the equipment under different frequency signals. For example... Figure 9 As shown in the figure, the dashed line represents the performance parameters of the improved network transformer. Compared with the original transformer, it has lower return loss and indicates that the improved network transformer of this application is more suitable for transmitting high-speed network signals of 10G and above.

[0116] It should be understood that the terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. Unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “described” as used herein may also include the plural forms. The terms “comprising,” “including,” “containing,” and “having” are inclusive and therefore indicate the presence of the stated features, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or combinations thereof. The method steps, processes, and operations described herein are not construed as requiring them to be performed in a particular order described or illustrated unless the order of performance is explicitly indicated. It should also be understood that additional or alternative steps may be used.

[0117] Although terms such as first, second, third, etc., may be used in this document to describe multiple elements, components, regions, layers, and / or segments, these elements, components, regions, layers, and / or segments should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or segment from another. Unless the context clearly indicates otherwise, terms such as "first," "second," and other numerical terms used herein do not imply order or sequence. Therefore, the first element, component, region, layer, or segment discussed below may be referred to as the second element, component, region, layer, or segment without departing from the teachings of the exemplary embodiments.

[0118] The above description is merely a specific embodiment of this application, enabling those skilled in the art to understand or implement this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

Claims

1. A network transformer, characterized in that, It includes a first magnetic ring, a second magnetic ring, at least one first winding, at least one second winding, at least one third winding, and at least one fourth winding; At least one of the fourth windings and at least one of the first windings are twisted together to form a first strand group, the first strand group being wound around the first magnetic ring at least one turn; At least one second winding and at least one third winding are twisted together to form a second strand group, the second strand group having the same number of turns as the first strand group wound around the first magnetic ring; The end of the first winding and the beginning of the third winding are twisted together on the outside of the first magnetic ring to form a first tap; The end of the second winding and the beginning of the fourth winding are twisted together on the outside of the first magnetic ring to form a second tap; The first end of the second winding and the end of the fourth winding are twisted together on the outside of the first magnetic ring to form a third twisted group, which is wound around the second magnetic ring at least one turn. In this configuration, on the outside of the first magnetic ring, the beginning of the first winding and the end of the third winding are wound in opposite directions around the two ends of the first stranded wire group and the two ends of the second stranded wire group.

2. The network transformer according to claim 1, characterized in that, The number of the first winding is at least two, and at least two of the first windings and the fourth winding are twisted together to form the first twisted group; The number of the third winding is the same as the number of the first winding, and at least two of the third windings are twisted together with the second winding to form the second twisted group; On the outside of the first magnetic ring, at least two ends of the first winding and at least two beginnings of the third winding are twisted together to form the first tap, at least two beginnings of the first winding are twisted together to form a first wire bundle, and at least two ends of the third winding are twisted together to form a second wire bundle. The first wire bundle and the second wire bundle are wound in opposite directions around the two ends of the first twisted wire group and the two ends of the second twisted wire group.

3. The network transformer according to claim 2, characterized in that, The first wire harness has at least 1 / 2 turns, the second wire harness has at least 1 / 2 turns, and the first and second wire harnesses have the same number of turns.

4. The network transformer according to claim 3, characterized in that, The first wire harness and the second wire harness are wound with 1 / 2 turn; Alternatively, the first and second wire harnesses may be wound one turn.

5. The network transformer according to any one of claims 1-4, characterized in that, The first stranded wire group and the second stranded wire group are wound around the first magnetic ring 3-7 times; and / or, The first stranded wire is wound around the arc length region corresponding to the central angle of the first magnetic ring, which is less than or equal to 240°.

6. The network transformer according to any one of claims 1-4, characterized in that, The third strand of wire is wound around the second magnetic ring 3-5 times; and / or, The second stranded wire is wound around the arc length region corresponding to the central angle of the second magnetic ring, which is less than or equal to 216°.

7. The network transformer according to any one of claims 1-4, characterized in that, The network transformer also includes: The fifth winding, the beginning of which is twisted together with the end of the second winding and the beginning of the fourth winding to form the second tap, and the end of which is twisted together with the beginning of the second winding and the end of the fourth winding to form the third twisted wire group.

8. The network transformer according to claim 7, characterized in that, The first stranded wire group and the second stranded wire group have the same degree of twist; and / or, In the first stranded wire group, the second stranded wire group, and the first tap, the twist ratio of the twisted pair structure is 26-34 strands per inch, the twist ratio of the twisted three structure is 16-24 strands per inch, and the twist ratio of the twisted four structure is 16-20 strands per inch; and / or, The second tap has a twist rate of 16-24 segments per inch; and / or, The twist rate of the third strand is 12-16 strands per inch.

9. The network transformer according to any one of claims 1-4, characterized in that, The end of the second tap has a solder joint area with a length of less than or equal to 6 mm.

10. The network transformer according to any one of claims 1-4, characterized in that, The diameter of the first magnetic ring is larger than the diameter of the second magnetic ring; and / or, The radial thickness of the first magnetic ring is less than or equal to 5 mm; and / or, The gap between the first magnetic ring and the second magnetic ring is less than or equal to 2 mm.

Images