Medium-high voltage high-frequency transformer

Abstract

The utility model relates to a high frequency transformer of medium and high voltage relates to the field of power electronics equipment especially relates to a high voltage impact resistance transformer assembly applied to high voltage energy storage and power conversion system, in order to realize above -mentioned purpose, the utility model discloses the following technical scheme is used: it includes magnetic core group, glue insulating shell, coil assembly, terminal lead -out piece, filling seal glue insulating layer and shell fixing mechanism, terminal lead -out piece sets up inside coil assembly, and the filling seal glue insulating layer is filled between coil assembly and terminal lead -out piece, and coil assembly outside is provided with magnetic core group, and the outside of magnetic core group is covered with shell fixing mechanism, the inside of coil assembly is provided with glue insulating shell, the magnetic core group is formed by the splicing of multiple sets of magnetic cores, and the magnetic core is E-shaped structure, and multiple sets of magnetic cores adopt glue and mutually adhere, coil assembly includes low voltage winding, high voltage winding and return winding in proper order, and the lead wire of low voltage winding leads out and is connected terminal, it provides a high voltage impact resistance transformer assembly, has higher withstand voltage performance, insulation reliability and stability, and is convenient for installation and maintenance.

Description

Technical Field

[0001] This utility model relates to the field of power electronic equipment, and in particular to a high-voltage shock-resistant transformer component used in high-voltage energy storage and power conversion systems. Background Technology

[0002] In existing high-voltage power conversion equipment (such as energy storage inverters, pulse power supplies, ion generators, etc.), high-voltage transformers with magnetic core structures are commonly used. However, when the insulation distance between high-voltage windings is insufficient, resin impregnation is uneven, or magnetic core assembly is misaligned, problems such as partial discharge and inter-turn breakdown can easily occur, affecting the reliability and service life of the product.

[0003] Traditional high-voltage transformers often face several design challenges: First, low core assembly precision can lead to unstable magnetic permeability; second, poor potting of coil windings can cause partial discharge and insufficient withstand voltage; and third, complex terminal lead-out structures make installation and maintenance difficult. With the increasing demands on transformer component performance in high-voltage power systems, existing technologies are no longer sufficient to meet the requirements for stability, reliability, and withstand voltage under high-voltage conditions. Utility Model Content

[0004] The purpose of this utility model is to address the defects and shortcomings of the existing technology by providing a medium-voltage high-frequency transformer. It provides a high-voltage impulse-resistant transformer assembly with higher withstand voltage performance, insulation reliability and stability, and is easy to install and maintain.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: it includes a magnetic core assembly 1, an adhesive insulating shell 2, a coil assembly 3, a terminal lead-out piece 4, a potting adhesive insulating layer 5, and a shell fixing mechanism 6; the terminal lead-out piece 4 is disposed inside the coil assembly 3, and a potting adhesive insulating layer 5 is filled between the coil assembly 3 and the terminal lead-out piece 4; the magnetic core assembly 1 is disposed on the outside of the coil assembly 3, and the shell fixing mechanism 6 is wrapped around the outside of the magnetic core assembly 1; the adhesive insulating shell 2 is disposed on the inside of the coil assembly 3.

[0006] The magnetic core assembly 1 is formed by splicing together multiple sets of magnetic cores 11. The magnetic core 11 has an E-shaped structure, and the multiple sets of magnetic cores 11 are bonded together with adhesive.

[0007] The coil assembly 3 includes a low-voltage winding, a high-voltage winding and a return winding in sequence, wherein the lead wire of the low-voltage winding is led out and connected to terminal 31.

[0008] The outer layer of the adhesive insulating shell 2 is covered with a polyimide tape layer 21.

[0009] After the coil assembly 3 is wound, it is injected with an epoxy resin system through a vacuum injection device to form a potting adhesive insulation layer 5.

[0010] The magnetic core assembly 1 and the glue-insulated outer shell 2 are bonded and fixed together by fasteners and epoxy adhesive.

[0011] The terminal lead-out component 4 is a copper wire terminal, and a cold-pressed terminal 41 is provided at the connection end of the copper wire terminal. The cold-pressed terminal 41 is used to connect to an external circuit.

[0012] The outer casing fixing mechanism 6 is a frame structure, and the magnetic core assembly 1 is enclosed within the outer casing fixing mechanism 6 to form an integrated structure. A metal fastener 61 is provided on the outer side of the outer casing fixing mechanism 6. The integrated design ensures the stability of the magnetic core 1, and the metal fastener 61 facilitates the overall installation and fixing.

[0013] The working principle of this invention is as follows: Multiple E-shaped magnetic cores are spliced ​​together and fixed with adhesive to form a core assembly, ensuring the stability and good magnetic permeability of the cores. The coil assembly includes a low-voltage winding, a high-voltage winding, and a return winding. The leads of the low-voltage winding are led out through copper wire terminals and connected to the external circuit. The entire coil assembly has a compact structure and is vacuum-sealed. The potting adhesive insulation layer effectively enhances the insulation performance and improves the withstand voltage. The core assembly is fixed to the adhesive-insulated shell using fasteners and epoxy adhesive, ensuring the rigidity and reliability of the entire assembly. The frame structure of the shell fixing mechanism covers the core assembly and is connected to the mounting base via metal fasteners, achieving a stable installation of the high-voltage transformer assembly. The terminal leads use copper wire terminals, and the connection ends are equipped with cold-pressed terminals, providing reliable electrical connections and simplifying the connection process to external circuits.

[0014] The beneficial effects of this invention, achieved by adopting the above technical solution, are as follows: By optimizing the splicing process of the magnetic core, improving the potting quality of the coil assembly, and refining the terminal lead-out structure, it effectively enhances the withstand voltage performance, insulation reliability, and stability of the transformer assembly. Especially under high-voltage conditions, the introduction of the potting adhesive insulation layer significantly reduces the risk of partial discharge, achieving up to 20,000V per mm, while ensuring stable operation over extended periods. Furthermore, the integrated design ensures a more secure fixation between the magnetic core assembly and the adhesive insulation shell, and the use of metal fasteners facilitates equipment installation and maintenance, greatly extending the product's lifespan and maintenance convenience. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a schematic diagram of the structure of this utility model; Figure 2 yes Figure 1 Another viewpoint; Figure 3 This is an exploded structural diagram of the present invention; Figure 4 This is a schematic diagram of the structure of the adhesive insulating shell 2 in this utility model; Figure 5 This is a schematic diagram of the internal structure of this utility model; Figure 6 yes Figure 5 Another aspect of humidity.

[0017] Explanation of reference numerals in the attached drawings: 1. Magnetic core assembly; 2. Adhesive insulating shell; 3. Coil assembly; 4. Terminal lead-out piece; 5. Potting adhesive insulating layer; 6. Shell fixing mechanism; 11. Magnetic core; 31. Connecting terminal; 21. Polyimide tape layer; 41. Cold-pressed terminal; 61. Metal fastener. Detailed Implementation

[0018] See Figure 1-6 As shown, the technical solution adopted in this specific embodiment is as follows: it includes a magnetic core assembly 1, an adhesive insulating shell 2, a coil assembly 3, a terminal lead-out piece 4, a potting adhesive insulating layer 5, and a shell fixing mechanism 6; the terminal lead-out piece 4 is disposed inside the coil assembly 3, and a potting adhesive insulating layer 5 is filled between the coil assembly 3 and the terminal lead-out piece 4; the magnetic core assembly 1 is disposed on the outside of the coil assembly 3, and the shell fixing mechanism 6 is wrapped around the outside of the magnetic core assembly 1; the adhesive insulating shell 2 is disposed on the inside of the coil assembly 3. The magnetic core assembly 1 is formed by splicing multiple sets of magnetic cores 11, the magnetic cores 11 having an E-shaped structure, and the multiple sets of magnetic cores 11 are bonded together with adhesive. The coil assembly 3 sequentially includes a low-voltage winding, a high-voltage winding, and a return winding, wherein the lead wire of the low-voltage winding is led out and connected to the terminal 31. The outer layer of the adhesive insulating shell 2 is covered with a polyimide tape layer 21. After the coil assembly 3 is wound, an epoxy resin system is injected through a vacuum potting device to form the potting adhesive insulating layer 5. The magnetic core assembly 1 is bonded and fixed to the adhesive insulating shell 2 using fasteners and epoxy adhesive. The terminal lead 4 uses copper wire terminals, and a cold-pressed terminal 41 is provided at the connection end of the copper wire terminal for connection to an external circuit. The shell fixing mechanism 6 is a frame structure, and the magnetic core assembly 1 is enclosed within the shell fixing mechanism 6 to form an integrated structure. A metal fastener 61 is provided on the outside of the shell fixing mechanism 6. The integrated design ensures the stability of the magnetic core 1, and the metal fastener 61 facilitates the overall installation and fixing.

[0019] The coil assembly 3 is made of copper wire, with a film-coated square wire size of 11.6mm × 6.2mm; the wire bundle has 0.1 × 4000 strands.

[0020] It forms a core assembly by splicing multiple E-shaped magnetic cores and fixing them with adhesive, ensuring the stability and good magnetic permeability of the cores. The coil assembly includes a low-voltage winding, a high-voltage winding, and a return winding. The leads of the low-voltage winding are led out through copper wire terminals and connected to the external circuit. The entire coil assembly has a compact structure and is vacuum-encapsulated. The potting adhesive insulation layer effectively enhances the insulation performance and improves the withstand voltage. The core assembly is fixed to the adhesive-insulated shell by fasteners and epoxy adhesive, ensuring the rigidity and reliability of the entire assembly. The frame structure of the shell fixing mechanism covers the core assembly and is connected to the mounting base by metal fasteners, achieving a stable installation of the high-voltage transformer assembly. The terminal leads use copper wire terminals, and the connection ends are equipped with cold-pressed terminals, which can provide reliable electrical connections and simplify the process of connecting external circuits.

[0021] By optimizing the core splicing process, improving the potting quality of the coil assembly, and refining the terminal lead-out structure, it effectively enhances the withstand voltage performance, insulation reliability, and stability of the transformer assembly. Especially under high-voltage environments, the introduction of the potting adhesive insulation layer significantly reduces the risk of partial discharge while ensuring stable operation over extended periods. Furthermore, the integrated design ensures a more secure fixation between the core assembly and the adhesive insulation shell, and the use of metal fasteners facilitates installation and maintenance, greatly extending the product's lifespan and ease of maintenance.

[0022] The above description is only used to illustrate the technical solution of this utility model and is not intended to limit it. Any other modifications or equivalent substitutions made by those skilled in the art to the technical solution of this utility model, as long as they do not depart from the spirit and scope of the technical solution of this utility model, should be covered within the scope of the claims of this utility model.

Claims

1. A medium-voltage high-frequency transformer, characterized in that: It includes a magnetic core assembly (1), an adhesive insulating shell (2), a coil assembly (3), a terminal lead (4), a potting adhesive insulating layer (5), and a shell fixing mechanism (6); the terminal lead (4) is located inside the coil assembly (3), and a potting adhesive insulating layer (5) is filled between the coil assembly (3) and the terminal lead (4); the magnetic core assembly (1) is located on the outside of the coil assembly (3), and the shell fixing mechanism (6) covers the outside of the magnetic core assembly (1); the adhesive insulating shell (2) is located on the inside of the coil assembly (3).

2. The medium-voltage high-frequency transformer according to claim 1, characterized in that: The magnetic core assembly (1) is formed by splicing together multiple sets of magnetic cores (11). The magnetic cores (11) have an E-shaped structure, and the multiple sets of magnetic cores (11) are glued together.

3. The medium-voltage high-frequency transformer according to claim 1, characterized in that: The coil assembly (3) includes a low-voltage winding, a high-voltage winding and a return winding in sequence, wherein the lead wire of the low-voltage winding is led out and connected to the terminal (31).

4. The medium-voltage high-frequency transformer according to claim 1, characterized in that: The outer layer of the adhesive insulating shell (2) is covered with a polyimide tape layer (21).

5. The medium-voltage high-frequency transformer according to claim 1, characterized in that: After the coil assembly (3) is wound, an epoxy resin system is injected through a vacuum potting device to form a potting adhesive insulation layer (5).

6. The medium-voltage high-frequency transformer according to claim 1, characterized in that: The magnetic core assembly (1) is fixed to the glue-insulated outer shell (2) by fasteners and epoxy adhesive.

7. The medium-voltage high-frequency transformer according to claim 1, characterized in that: The terminal lead-out component (4) adopts a copper wire terminal, and a cold-pressed terminal (41) is provided at the connection end of the copper wire terminal. The cold-pressed terminal (41) is used to connect to an external circuit.

8. The medium-voltage high-frequency transformer according to claim 1, characterized in that: The outer shell fixing mechanism (6) is a frame structure. The magnetic core assembly (1) is enclosed in the outer shell fixing mechanism (6) to form an integral structure. Metal fasteners (61) are provided on the outside of the outer shell fixing mechanism (6).

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