Safety ring transformer with increased leakage inductance
Patent Information
- Application Number
- CN202521451681.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-07-11
- Publication Date
- 2026-10-27
- Estimated Expiration
- 2035-07-11
AI Technical Summary
[0004]本申请的目的是提供增大漏感安全环形变压器，具备安装位置占用较小的优点，解决了目前环形变压器大多数为卧式安装，卧式安装时，通常由环形变压器的直径，决定其安装占用的空间，因此占用空间较大，在紧凑型设备中由于空间不足可能会导致环形变压器的安装困难
该增大漏感安全环形变压器，通过固定筒与夹板组合的垂直安装装置，通过安装螺栓将传统卧式变压器改为立式安装，用于节省设备内部的水平空间，还通过增大与空气的接触面积提升了散热效率，通过精确控制初级与次级绕组的间距和缠绕方式，主动增大漏感量，在开关电源应用中可有效吸收瞬时高压尖峰，限制电流突变速度，保护功率器件免受损坏，并通过采用聚酰亚胺薄膜和漆包线的双重绝缘设置，聚酰亚胺薄膜具有优异的耐高温性能和长期稳定性，确保绕组间可靠隔离，漆包线则提供了薄而均匀的绝缘层，在有限空间内实现更高功率密度，外包裹的压敏胶带不仅形成防潮密封屏障，还能吸收变压器工作时的微振动，降低运行噪音，接线端子采用双插槽布局和螺丝压接方式，提高了接线效率，又确保了连接的可靠性，端子本体的对称插槽设计引导导线精准插入，避免接触不良，而可调节的压紧螺丝则能适应不同线径，抵抗振动导致的松动，该装置通过优化安装空间和便捷接线方案，立式结构便于减少该装置在设备内的安装占用空间，通过接线端子的设置增加了与导线之间的接线稳定性。
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Abstract
Description
Technical Field
[0001] This application relates to the field of toroidal transformer technology, and in particular to a toroidal transformer with increased leakage inductance for safety. Background Technology
[0002] Toroidal transformers are a major type of electronic transformer and are widely used in household appliances and other high-tech electronic equipment. Their main uses are as power transformers and isolation transformers. Toroidal transformers have a complete series abroad and are widely used in computers, medical equipment, telecommunications, instruments and lighting.
[0003] However, most toroidal transformers are currently installed horizontally. When installed horizontally, the space occupied by the toroidal transformer is usually determined by its diameter, so it occupies a large space. In compact equipment, insufficient space may make the installation of toroidal transformers difficult. Utility Model Content
[0004] The purpose of this application is to provide a toroidal transformer with increased leakage inductance safety, which has the advantage of occupying less installation space. This solves the problem that most toroidal transformers are currently installed horizontally. When installed horizontally, the space occupied by the toroidal transformer is usually determined by the diameter of the toroidal transformer, which can lead to a large space requirement. In compact equipment, insufficient space may make the installation of the toroidal transformer difficult.
[0005] The increased leakage inductance safety toroidal transformer provided in this application adopts the following technical solution: The increased leakage inductance safety toroidal transformer includes a shell, a mounting plate, and a clamping plate. A coil winding is fixedly connected inside the shell. Lead wires are fixedly connected to the leads of the coil windings that pass through the shell. A terminal block is fixedly connected to the ends of the multiple leads in pairs away from the shell. A fixing cylinder is fixedly connected to one side of the mounting plate. A second threaded hole is opened at the end of the fixing cylinder away from the mounting plate. A through hole is opened inside the clamping plate. A mounting bolt is slidably connected inside the through hole. A base plate is fixedly connected to the bottom of both the mounting plate and the clamping plate. A mounting hole is opened inside both base plates.
[0006] By adopting the above technical solution, the traditional horizontal transformer is transformed into a vertical installation through the setting of the fixed cylinder and clamp plate, and the use of mounting bolts. This saves internal space, makes the overall layout more compact and reasonable, and provides more flexibility for the arrangement of other components. The vertical installation structure increases the contact area between the transformer and the surrounding air, improving heat dissipation efficiency and ensuring that the transformer maintains a stable operating temperature during long-term operation. Furthermore, the use of standardized terminals instead of traditional welding or winding methods makes installation and maintenance more convenient and reduces the risk of electrical faults caused by poor contact. This device has the advantages of optimizing space utilization, increasing heat dissipation performance, and improving electrical safety through vertical installation. It solves the shortcomings of traditional transformers in terms of space occupation, heat dissipation effect, and operational safety, and is suitable for use in electronic equipment with high requirements for space utilization and safety.
[0007] Preferably, the outer wall of the outer shell is wrapped with wrapping tape.
[0008] By adopting the above technical solution, the wrapping tape and the outer shell form a double insulation barrier. Safety markings or equipment information can be printed on the wrapping tape. Installers can quickly identify the wiring method or dangerous areas through the markings on the wrapping tape, reducing operational errors.
[0009] Preferably, the coil winding includes a magnetic core, a first insulating film is disposed on the outer wall of the magnetic core, a primary winding is disposed on the outer wall of the first insulating film in a spiral arrangement, a second insulating film is disposed on the outer wall of the primary winding, and a secondary winding is disposed on the outer wall of the second insulating film in a spiral arrangement.
[0010] By adopting the above technical solution, the leakage inductance can be actively increased by adjusting the spacing, number of layers and winding method of the primary winding and secondary winding. In the switching power supply, when the switching transistor is turned off, the leakage inductance can absorb the instantaneous high voltage spike, preventing the power device from being damaged by overvoltage breakdown. The leakage inductance limits the current change rate, preventing the components from overheating or burning out due to the sudden increase in current, and improving the reliability of the equipment.
[0011] Preferably, both terminals include a terminal body, and two slots arranged in a mirror image are provided on one side of the interior of each terminal body. Two first threaded holes arranged in a mirror image are provided on one side of the upper end of each terminal body, and a clamping screw is threaded into each of the two first threaded holes.
[0012] By adopting the above technical solution, two mirror-distributed slots are opened inside each terminal body, which can accommodate two wires at the same time. In multi-wire connection scenarios, the two slots can improve wiring efficiency. The symmetrical slots guide the wires to be inserted accurately, avoiding poor contact or short circuits caused by positional deviation. Two first threaded holes are opened at the top of each terminal body. The wires inserted into the slots are firmly fixed by clamping screws. During equipment operation or transportation, the screw tightening can resist the wires from falling off due to vibration and maintain a long-term stable connection. The cooperation between the first threaded holes and the clamping screws allows users to adjust the tightening force according to the wire material.
[0013] Preferably, the fixed cylinder is slidably disposed on the inner wall of the outer shell, the clamping plate is disposed at the end of the fixed cylinder away from the clamping plate, and the end of the mounting bolt that passes through the through hole is threaded inside the second threaded hole.
[0014] By adopting the above technical solution, the fixed cylinder is slidably set on the inner wall of the outer shell, so that it is between the clamping plate and the mounting plate. By passing the mounting bolt through the through hole and connecting it with the threaded hole, the toroidal transformer is transformed into a vertical state, thereby reducing the installation space occupied by the traditional horizontal installation.
[0015] Preferably, both the first insulating film and the second insulating film are polyimide films.
[0016] By adopting the above technical solution, the transformer winding is made of multiple turns of wire tightly wound together. The turns need to be insulated to prevent short circuits. The primary and secondary windings need to be strictly insulated to prevent the high-voltage side current from leaking to the low-voltage side, causing electric shock or equipment damage. Polyimide has relatively stable insulation properties and is not prone to insulation failure due to aging or moisture during long-term use. The polyimide film also has high high temperature resistance to ensure that the inter-turn insulation does not soften or fall off under high temperature conditions, avoiding short circuit faults, fire or electric shock risks.
[0017] Preferably, both the primary winding and the secondary winding are made of enameled wire.
[0018] By adopting the above technical solutions, the insulation varnish layer of the enameled wire can effectively isolate the electrical contact between windings, prevent short circuit accidents, and has high withstand voltage strength, which can withstand the voltage impact during transformer operation, ensuring long-term stable operation. The insulation layer of the enameled wire is thin and uniform, allowing more turns to be wound in the same space, thereby increasing the power density of the transformer. The enameled wire winding process is simple and reliable, facilitating mass production, ensuring product consistency, and reducing production costs.
[0019] Preferably, the wrapping tape is a pressure-sensitive tape.
[0020] By adopting the above technical solution, the pressure-sensitive tape layer forms a continuous and sealed package, effectively blocking the intrusion of pollutants such as moisture and dust in the air, protecting the internal insulation material from moisture erosion, and the elastic substrate of the tape can absorb the micro-vibrations generated by magnetostriction when the transformer is working, reducing operating noise and improving the equipment's quietness performance.
[0021] In summary, this application includes at least one of the following beneficial technical effects: This increased leakage inductance safety toroidal transformer utilizes a vertical mounting device combining a fixed cylinder and clamping plates, converting the traditional horizontal transformer into a vertical installation via mounting bolts. This saves internal horizontal space and improves heat dissipation efficiency by increasing the contact area with air. By precisely controlling the spacing and winding method of the primary and secondary windings, the leakage inductance is actively increased. In switching power supply applications, this effectively absorbs instantaneous high-voltage spikes, limits the rate of current change, and protects power devices from damage. Furthermore, the use of double insulation with polyimide film and enameled wire ensures reliable isolation between windings. The polyimide film, with its excellent high-temperature resistance and long-term stability, provides reliable insulation, while the enameled wire offers thin and... The uniform insulation layer achieves higher power density within a limited space. The outer pressure-sensitive tape not only forms a moisture-proof sealing barrier but also absorbs the micro-vibrations during transformer operation, reducing operating noise. The terminals adopt a double-slot layout and screw crimping method, improving wiring efficiency and ensuring connection reliability. The symmetrical slot design of the terminal body guides the wires for precise insertion, avoiding poor contact, while the adjustable clamping screws can adapt to different wire diameters and resist loosening caused by vibration. This device optimizes installation space and provides a convenient wiring solution. The vertical structure reduces the space occupied by the device within the equipment, and the terminal block configuration increases the stability of the wiring with the wires. Attached Figure Description
[0022] Figure 1 This is a schematic diagram of the overall structure of this application; Figure 2 This is a schematic diagram of the coil winding installation structure of this application. Figure 3 This is a schematic diagram of the mounting base structure of this application; Figure 4 This is a cross-sectional view of the coil winding structure of this application. Figure 5 This is a schematic diagram of the wiring terminal structure of this application.
[0023] In the picture: 1. Outer casing; 2. Coil winding; 201. Magnetic core; 202. First insulating film; 203. Primary winding; 204. Secondary insulating film; 205. Secondary winding; 3. Lead wire; 4. Terminal block; 401. Terminal body; 402. Slot; 403. First threaded hole; 404. Clamping screw; 5. Mounting plate; 6. Fixing sleeve; 7. Second threaded hole; 8. Clamping plate; 9. Through hole; 10. Mounting bolt; 11. Base plate; 12. Mounting hole; 13. Wrapping tape. Detailed Implementation
[0024] The following is in conjunction with the appendix Figure 1 - Appendix Figure 5 This application will be described in further detail below.
[0025] Example 1: Increase leakage inductance safety toroidal transformer, refer to Figure 1 , Figure 2 and Figure 3 The device includes a housing 1, a mounting plate 5, and a clamping plate 8. A coil winding 2 is fixedly connected inside the housing 1. Leads 3 are fixedly connected to the leads of the coil winding 2, passing through the housing 1. The leads 3 are used to connect the device to wires. Multiple leads 3 are grouped in pairs, with terminals 4 fixedly connected to the ends furthest from the housing 1. The use of standardized terminals 4 instead of traditional welding or winding methods makes installation and maintenance more convenient and reduces the risk of electrical faults due to poor contact. A fixing cylinder 6 is fixedly connected to one side of the mounting plate 5. A second threaded hole 7 is opened at the end of the fixing cylinder 6 furthest from the mounting plate 5. A through hole 9 is opened inside the clamping plate 8, and a mounting bolt 10 is slidably connected inside the through hole 9. The fixing cylinder 6 and the clamping plate 8 are used for installation... Bolt 10 transforms the traditional horizontal transformer into a vertical installation method, thereby saving internal space and making the overall layout more compact and reasonable. It also provides more flexibility for the arrangement of other components. The vertical installation structure increases the contact area between the transformer and the surrounding air, improving heat dissipation efficiency and ensuring that the transformer maintains a stable operating temperature during long-term operation. The bottom of the mounting plate 5 and the clamping plate 8 are both fixedly connected to the base plate 11. Both base plates 11 have mounting holes 12 inside. The outer wall of the outer shell 1 is wrapped with wrapping tape 13, which forms a double insulation barrier with the outer shell 1. Safety markings or equipment information can be printed on the wrapping tape 13. Installers can quickly identify the wiring method or dangerous areas through the markings on the wrapping tape 13, reducing operational errors.
[0026] Example 2: Increased leakage inductance safety toroidal transformer, refer to Figure 3 , Figure 4 and Figure 5The coil winding 2 includes a magnetic core 201. A first insulating film 202 is disposed on the outer wall of the magnetic core 201. A primary winding 203, spirally wound, is disposed on the outer wall of the first insulating film 202. A second insulating film 204 is disposed on the outer wall of the primary winding 203. A secondary winding 205, spirally wound, is disposed on the outer wall of the second insulating film 204. By adjusting the spacing, number of layers, and winding method of the primary winding 203 and the secondary winding 205, the leakage inductance can be actively increased. In a switching power supply, when the switching transistor is turned off, the leakage inductance can absorb instantaneous high-voltage spikes, preventing power devices from being damaged by overvoltage breakdown. The leakage inductance limits the rate of current change, preventing components from overheating or burning out due to a sudden increase in current, thus improving equipment reliability. Both terminals 4 include end... The two terminal bodies 401 each have two mirror-shaped slots 402 on one side inside their interiors, and two mirror-shaped first threaded holes 403 on one side of their upper ends. Each of the first threaded holes 403 has a threaded clamping screw 404 threaded inside. The two mirror-shaped slots 402 inside each terminal body 401 can accommodate two wires simultaneously. In multi-wire connection scenarios, the two slots 402 improve wiring efficiency. The symmetrical slots 402 guide the wires to be inserted accurately, avoiding poor contact or short circuits caused by positional deviations. The two first threaded holes 403 on the upper end of each terminal body 401 are used to secure the wires inserted into the slots 402 with the clamping screws 404. The screws are securely tightened to prevent wires from coming loose due to vibration during equipment operation or transportation, maintaining a long-term stable connection. The engagement of the first threaded hole 403 and the clamping screw 404 allows users to adjust the tightening force according to the wire material. The fixing cylinder 6 is slidably mounted on the inner wall of the outer casing 1, and the clamping plate 8 is located at the end of the fixing cylinder 6 away from the clamping plate 8. The mounting bolt 10 passes through the through hole 9 and is threaded into the second threaded hole 7. Each terminal body 401 has two mirror-shaped slots 402 inside, which can accommodate two wires simultaneously. In multi-wire connection scenarios, the two slots 402 can improve wiring efficiency. The symmetrical slots 402 guide the wires to be inserted accurately, avoiding poor contact or short circuits caused by positional deviations. Two first threaded holes 403 are provided at the upper end of 401. A clamping screw 404 securely fixes the wire inserted into the slot 402. During equipment operation or transportation, the tightened screws prevent wires from falling off due to vibration, maintaining a long-term stable connection. The fit between the first threaded holes 403 and the clamping screw 404 allows the user to adjust the tightening force according to the wire material. Both the first insulating film 202 and the second insulating film 204 are polyimide films. The transformer windings are composed of multiple tightly wound turns of wire, with inter-turn insulation to prevent short circuits. The primary and secondary windings 205 require strict insulation to prevent current leakage from the high-voltage side to the low-voltage side, which could cause electric shock or equipment damage. Polyimide has relatively stable insulation properties and is not prone to insulation failure due to aging or moisture over long-term use.The polyimide film also possesses high high-temperature resistance, ensuring that the inter-turn insulation does not soften or detach under high-temperature conditions, avoiding short-circuit faults, fires, or electric shock risks. Both the primary winding 203 and the secondary winding 205 are made of enameled wire. The insulating varnish layer of the enameled wire effectively isolates electrical contacts between windings, preventing short-circuit accidents. Its high withstand voltage strength allows it to withstand voltage surges during transformer operation, ensuring long-term stable operation. The thin and uniform insulation layer of the enameled wire allows for more turns to be wound in the same space, increasing the transformer's power density. The enameled wire winding process is simple and reliable, facilitating mass production, ensuring product consistency, and reducing production costs. The wrapping tape 13 is a pressure-sensitive tape. The tape layer forms a continuous, sealed wrap, effectively blocking the intrusion of moisture, dust, and other contaminants in the air, protecting the internal insulation material from moisture erosion. The elastic substrate of the tape absorbs the micro-vibrations generated by magnetostriction during transformer operation, reducing operating noise and improving the equipment's quietness.
[0027] The implementation principle of this application embodiment is as follows: The magnetic core 201 of coil winding 2 is sequentially wrapped with a first insulating film 202, a primary winding 203, a second insulating film 204, and a secondary winding 205. By adjusting the spacing, number of layers, and winding method of the primary winding 203 and the secondary winding 205, the leakage inductance is actively increased. In a switching power supply, this can absorb the instantaneous high-voltage spike when the switching transistor is turned off, limit the rate of current change, prevent damage to power devices, and improve equipment reliability. The first insulating film 202 and the second insulating film 204 are both made of polyimide film, while the primary winding 203 and the secondary winding 205 are made of enameled wire, forming multiple insulation barriers to prevent short circuits and current leakage, ensuring safe use. The lead-out end of coil winding 2 is connected to terminal 4 via lead-out wire 3, and the slot 402 of terminal body 401... It can accommodate two wires at the same time. The clamping screw 404 firmly fixes the wires through the threaded hole. The standardized terminal block 4 makes installation and maintenance more convenient and reduces the risk of poor contact. During installation, the outer shell 1 is slidably fitted onto the outer wall of the fixing cylinder 6, and the toroidal transformer is converted into a vertical installation by using the mounting plate 5 and clamp 8 in conjunction with the mounting bolts 10, which saves space and increases the contact area with air, thereby improving heat dissipation efficiency. The mounting holes 12 of the base plate 11 facilitate overall fixation. The pressure-sensitive tape wrapped around the outer wall of the outer shell 1 forms a sealed barrier to prevent the intrusion of contaminants, absorb micro-vibrations and reduce noise. At the same time, safety markings can be printed to facilitate the operation of installers. The whole system achieves the functions of increased leakage inductance, safe insulation and convenient installation through the cooperation of various components, ensuring the stable and safe operation of the transformer.
[0028] The embodiments described in this specific implementation are preferred embodiments of this application and are not intended to limit the scope of protection of this application. Identical components are represented by the same reference numerals. Therefore, all equivalent changes made to the structure, shape, and principle of this application should be covered within the scope of protection of this application.
Claims
1. A toroidal transformer with increased leakage inductance, comprising a casing (1), a mounting plate (5), and a clamping plate (8), characterized in that: The outer shell (1) is fixedly connected to a coil winding (2). The lead-out ends of the coil winding (2) are fixedly connected to lead wires (3) through the outer shell (1). The lead wires (3) are fixedly connected to terminals (4) at the ends away from the outer shell (1) in pairs. A fixing cylinder (6) is fixedly connected to one side of the mounting plate (5). A second threaded hole (7) is opened at the end of the fixing cylinder (6) away from the mounting plate (5). A through hole (9) is opened inside the clamping plate (8). A mounting bolt (10) is slidably connected inside the through hole (9). A base plate (11) is fixedly connected to the bottom of both the mounting plate (5) and the clamping plate (8). A mounting hole (12) is opened inside both base plates (11).
2. The increased leakage inductance safety toroidal transformer according to claim 1, characterized in that: The outer wall of the outer shell (1) is wrapped with wrapping tape (13).
3. The increased leakage inductance safety toroidal transformer according to claim 1, characterized in that: The coil winding (2) includes a magnetic core (201), the outer wall of the magnetic core (201) is provided with a first insulating film (202), the outer wall of the first insulating film (202) is provided with a primary winding (203) arranged in a spiral, the outer wall of the primary winding (203) is provided with a second insulating film (204), and the outer wall of the second insulating film (204) is provided with a secondary winding (205) arranged in a spiral.
4. The increased leakage inductance safety toroidal transformer according to claim 1, characterized in that: Both of the terminal blocks (4) include a terminal body (401). Two slots (402) are provided on one side of the interior of each of the two terminal bodies (401) in a mirror arrangement. Two first threaded holes (403) are provided on one side of the upper end of each of the two terminal bodies (401) in a mirror arrangement. A clamping screw (404) is threaded inside each of the two first threaded holes (403).
5. The increased leakage inductance safety toroidal transformer according to claim 1, characterized in that: The fixed cylinder (6) is slidably disposed on the inner wall of the outer shell (1), the clamping plate (8) is disposed at the end of the fixed cylinder (6) away from the clamping plate (8), and the mounting bolt (10) is threaded at one end of the through hole (9) inside the second threaded hole (7).
6. The increased leakage inductance safety toroidal transformer according to claim 3, characterized in that: Both the first insulating film (202) and the second insulating film (204) are polyimide films.
7. The increased leakage inductance safety toroidal transformer according to claim 3, characterized in that: Both the primary winding (203) and the secondary winding (205) are made of enameled wire.
8. The increased leakage inductance safety toroidal transformer according to claim 2, characterized in that: The wrapping tape (13) is a pressure-sensitive tape.