A high-frequency transformer with a multi-insulation structure

Abstract

The utility model discloses a kind of high-frequency transformer with multiple insulation structure, including magnetic core, primary winding, secondary winding and insulation structure, the primary winding and secondary winding are located in the corresponding position of magnetic core, the insulation structure includes the multilayer insulation sheet between winding, the first insulation layer between winding and magnetic core, the outer insulation shell of cladding winding and filling in its between potting material. By setting multiple insulation structure, the overall insulation performance and safety of transformer are improved, suitable for high-frequency high-voltage application occasion.

Description

Technical Field

[0001] This utility model relates to the field of high-frequency power supply equipment technology, and in particular to a high-frequency transformer with multiple insulation structures. Background Technology

[0002] High-frequency transformers are widely used in switching power supplies, inverters, and charging equipment, undertaking the critical functions of voltage transformation and electrical isolation. Traditional high-frequency transformers typically use only one layer of insulation material for isolation, such as enameled wire or a single layer of insulating tape, which is insufficient to meet the withstand voltage requirements under high-frequency and high-voltage conditions. Especially in continuous operation or extreme environments such as high temperature and humidity, existing structures are prone to insulation aging and breakdown, affecting system stability and safety.

[0003] To improve insulation performance, some solutions attempt to increase the spacing between windings or use high-insulation-grade materials. However, this usually leads to an increase in transformer size, a decrease in winding compactness, and even an increase in manufacturing difficulty, making it difficult to simultaneously meet the requirements of miniaturization and high performance. Therefore, there is an urgent need for a high-frequency transformer structure that is compact, has excellent insulation performance, and is easy to mass-produce. Summary of the Invention

[0004] The purpose of this utility model is to provide a high-frequency transformer with a multi-layer insulation structure. By setting up multiple layers of insulating sheets, a first insulating layer, an outer insulating shell, and an insulating lead-out channel, a multi-layer insulation protection system is formed, which significantly improves its withstand voltage and operational reliability under high-frequency and high-voltage environments.

[0005] To achieve the above objectives, this utility model provides the following technical solution: a high-frequency transformer with a multi-layer insulation structure, comprising a magnetic core, a primary winding, a secondary winding, and a multi-layer insulation structure, specifically including: At least two layers of insulating sheets are provided between the primary and secondary windings to effectively block electric field coupling between the windings; A first insulating layer is provided between the winding and the magnetic core to prevent the winding from being broken down due to the induced voltage in the magnetic core. The outer layer is equipped with a flame-retardant insulating shell to enhance mechanical protection and external insulation; Silicone or epoxy resin is potted between the winding and the housing to improve thermal conductivity and further enhance insulation. An insulated lead-out channel with a sleeve structure is set at the electrical lead-out end to prevent creepage or arcing.

[0006] The beneficial effects of this utility model are as follows: under the premise of compact structure, the overall insulation level is improved by multi-layer insulation system, which solves the problem of weak insulation of traditional structure in high voltage and high frequency environment, and has good practicality and industrial application value. Attached Figure Description

[0007] Figure 1 This is a schematic diagram of the overall structure of the high-frequency transformer of this utility model.

[0008] Figure 2 This is a cross-sectional view of the layered structure of the winding and the insulating sheet.

[0009] Figure 3 This is an enlarged view of the structure of the insulated lead-out channel.

[0010] Figure 4 This is a schematic cross-sectional view of the potting structure.

[0011] Figure 5 This is a diagram showing the material distribution of each insulating layer. Figure 6 This is a schematic diagram of an alternating stacked structure of insulating sheets.

[0012] Explanation of reference numerals in the attached diagram: 1. Magnetic core; 2. Primary winding; 3. Secondary winding; 4. Insulating sheet; 5. Insulating shell; 6. First insulating layer; 7. Encapsulating material; 8. Insulating lead-out channel; 9. Buffer pad; 5a. Dielectric particles. Detailed Implementation

[0013] Implementation method one: such as Figure 1-2 and Figure 6 As shown, the high-frequency transformer includes a magnetic core 1, a primary winding 2, and a secondary winding 3. The two windings are wound around corresponding positions on the magnetic core. The primary winding 2 uses a multi-layer lap winding method, with an insulating sheet 4 sandwiched between each layer to enhance interlayer insulation performance. The secondary winding 3 can be single-layer or segmented, flexibly arranged according to voltage output requirements. Two layers of polyimide insulating sheets 4 are sandwiched between the primary and secondary windings to form an electric field shielding layer between the primary and secondary windings. Each insulating sheet has a regularly distributed micro-bump structure on its surface, or several dielectric particles 5a are sandwiched as spacers, thereby forming uniform micro-gaps between the insulating sheets, effectively extending the insulation path and enhancing electrical isolation capability. Figure 6 The staggered arrangement and spacing of the insulating sheet 4 are further illustrated, which helps to understand the construction layers and electrical function of the multi-layer insulation structure.

[0014] Implementation Method Two: (e.g.) Figure 2 As shown, a first insulating layer 6 is attached between the winding and the magnetic core 1. This layer is an epoxy resin layer, preferably an epoxy resin film, which is tightly bonded and effectively avoids local breakdown of the winding near the magnetic core caused by high-frequency induction.

[0015] Implementation Method 3: For example Figure 1 and Figure 4As shown, after the primary winding 2 and secondary winding 3 are wound together, they are completely encapsulated in an insulating shell 5 made of flame-retardant polycarbonate, and an epoxy potting material 7 is injected between them. The material fills the gap between the shell and the windings, improving heat dissipation and insulation strength. The potting process is carried out using bottom injection + vacuum extraction to avoid air bubbles and ensure uniform potting. After potting, it is cured at room temperature for 24 hours, or a heat curing process can be selected according to the material properties. The potting material 7 is preferably silicone gel, but epoxy potting compound can also be used, which has excellent insulation and thermal conductivity properties. The specific selection can be adjusted according to the application scenario.

[0016] Implementation Method Four: (e.g.) Figure 3 As shown, the electrical connection lead-out end is provided with an insulated lead-out channel 8. This channel has a through-hole structure with an inner nested tube, preventing the wire from directly contacting the edge of the outer shell, avoiding sharp-angle discharge and creepage, and improving the electrical safety of the connection end. After the wire passes through the sleeve, it is covered with heat-shrink tubing and fixed to the inner wall of the sleeve with insulating adhesive, ensuring stable connection and good insulation at the lead-out end, preventing moisture or dust from entering and causing performance degradation. The sleeve of the insulated lead-out channel can be made of epoxy fiberglass tubing or ceramic sheathing, which has excellent insulation performance and heat resistance. The through-hole diameter is preferably 1.5mm to 3.0mm to adapt to the through-hole lead-out requirements of different specifications of wires and to ensure the insulation and sealing reliability of the overall structure.

[0017] Implementation Method 5: (e.g.) Figure 1 As shown, the buffer housing 5 and the magnetic core 1 are in rigid contact. A buffer pad 9 is added between them to absorb assembly stress and to form an additional insulating gap, thereby enhancing the overall insulation withstand capability of the structure. The buffer pad 9 can be made of silicone rubber or flexible epoxy gasket and is fixed between the housing 5 and the magnetic core 1 by adhesive or sliding. Its position can be set according to the positioning groove defined by the internal structure of the housing to ensure stable positioning without affecting the flow of insulating adhesive. The buffer pad 9 can be designed with a corrugated or honeycomb structure to enhance its elastic deformation capability and pressure distribution performance, thereby more effectively absorbing mechanical assembly stress and maintaining a stable insulating gap.

[0018] The above embodiments are merely preferred structures of this utility model. The number of insulation layers, material types, and size distribution can be adjusted according to different usage scenarios, and all of these fall within the protection scope of this utility model.

Claims

1. A high-frequency transformer with multiple insulation structures, comprising a magnetic core (1), a primary winding (2), and a secondary winding (3), characterized in that: The primary winding (2) and the secondary winding (3) are respectively wound on the magnetic core (1), and at least two layers of insulating sheets (4) are provided between them. The windings (2) and (3) are covered with an insulating shell (5). A first insulating layer (6) is provided between the windings (2) and (3) and the magnetic core (1). The windings and the shell are filled with potting material (7), and an insulating lead-out channel (8) is provided at the electrical connection lead-out end.

2. The high-frequency transformer according to claim 1, characterized in that: The insulating sheet (4) is made of polyimide material.

3. The high-frequency transformer according to claim 1, characterized in that: The first insulating layer (6) is an epoxy resin layer.

4. The high-frequency transformer according to claim 1, characterized in that: The insulating housing (5) is made of flame-retardant polycarbonate.

5. The high-frequency transformer according to claim 1, characterized in that: The potting material (7) is silicone gel or epoxy potting compound.

6. The high-frequency transformer according to claim 1, characterized in that: The insulating lead-out channel (8) is a through-hole structure with an internal sleeve.

7. The high-frequency transformer according to claim 1, characterized in that: The insulating sheet (4) is arranged in an alternating superposition.

8. The high-frequency transformer according to claim 1, characterized in that: A buffer pad (9) is provided between the insulating shell (5) and the magnetic core (1).

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