CN116110697A - Flat coil type high-power transformer - Google Patents
Flat coil type high-power transformer Download PDFInfo
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- CN116110697A CN116110697A CN202310234817.4A CN202310234817A CN116110697A CN 116110697 A CN116110697 A CN 116110697A CN 202310234817 A CN202310234817 A CN 202310234817A CN 116110697 A CN116110697 A CN 116110697A
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- coil
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- inner ring
- outer ring
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/2871—Pancake coils
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/29—Terminals; Tapping arrangements for signal inductances
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/30—Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support
- H01F27/306—Fastening or mounting coils or windings on core, casing or other support
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Coils Of Transformers For General Uses (AREA)
Abstract
The invention discloses a high-power transformer of a flat coil type, which comprises a primary winding, a secondary winding and a transformer magnetic core assembly, wherein one of the primary winding and the secondary winding comprises more than two inner coils which are arranged in a vertically stacked manner, and the other one comprises more than two outer coils which are arranged in a vertically stacked manner; each inner ring coil and a corresponding outer ring coil are arranged in the same layer, the outer ring coil is provided with an inner ring cavity, and the inner ring coil is arranged in the inner ring cavity of the outer ring coil and is concentric with the outer ring coil. Therefore, by adopting the vertically-wound flat coil inner and outer combined design, the area of the magnetic core window can be effectively utilized, the turn ratio of the flat coil is improved, the product height is reduced, the product volume is reduced, meanwhile, the structure is simple, the product design and production are easier to manage and control, the cost is low, and the high transmission power can be realized on the premise of small volume, and the reliability is good.
Description
Technical Field
The invention relates to the technical field of transformers, in particular to a high-power transformer with flat coils.
Background
The traditional high-power transformer is influenced by the flat wire coil process, the conventional flat wire design can only arrange one layer, when the output turns of the secondary flat wire structure are more, the requirement of multi-turn ratio can only be realized by increasing the stacking height space of the transformer, but the requirements of the multi-turn ratio of the flat wire and the secondary multi-group output can not be met due to the limitation of the height and the volume.
For example CN 208796794U, which discloses a miniaturized high power transformer assembly; the coil comprises a magnetic core, primary sides of N annular pancake coils which are sequentially wound by a multi-layer insulating wire and are in a serial connection shape, and secondary sides of N+1 flat coils which are independently made of enameled flat copper wires; n annular pancake coils and N+1 flat coils are alternately overlapped and assembled on the middle column of the magnetic core. The coil structure has low utilization rate of the area of the window of the magnetic core, and the whole height of the coil is required to be increased to be equal to the height of the transformer to be increased or the area vertical to the height direction to be increased under the condition of unchanged original height, so that the volume of the transformer product is required to be increased.
Therefore, a new technical solution is needed to solve the above problems.
Disclosure of Invention
In view of the above, the present invention aims at overcoming the disadvantages of the prior art, and its main objective is to provide a high-power transformer with flat coils, which adopts the combined design of the inner and outer of the vertically wound flat coils, so as to effectively utilize the area of the window of the magnetic core, increase the turn ratio of the flat coils, reduce the product height, and reduce the product volume.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
a high-power transformer of flat coil type comprises a primary winding, a secondary winding and a transformer magnetic core assembly;
one of the primary winding and the secondary winding comprises more than two inner ring coils which are arranged in a vertically stacked mode, and the other one of the primary winding and the secondary winding comprises more than two outer ring coils which are arranged in a vertically stacked mode; the inner ring coil and the outer ring coil are respectively formed by vertically winding flat wires to form flat wire flat coils with coil spiral parts at different heights, each inner ring coil and a corresponding outer ring coil are arranged on the same layer, the outer ring coil is provided with an inner ring cavity, and the inner ring coil is arranged in the inner ring cavity of the outer ring coil and is arranged concentrically with the outer ring coil;
and the bottom of the transformer magnetic core assembly is provided with an insulating positioning plate which is used for positioning the leading-out pin of the inner ring coil and the leading-out pin of the outer ring coil.
As a preferred solution, the pins of the inner loop coils of the different layers are arranged in series or in parallel.
As a preferred solution, the pins of the outer loop coils of the different layers are arranged in series or in parallel.
As a preferable scheme, the upper side or the lower side of the flat wire flat coil is provided with a round wire flat coil, the round wire flat coil is spirally and circumferentially arranged from inside to outside by a round wire, and coil spiral parts of the round wire flat coil are positioned on the same horizontal plane.
As a preferred scheme, one end leading-out pin of a plurality of inner ring coils is connected into one common leading-out pin of the inner ring coils, the other end leading-out pin of a plurality of inner ring coils is connected into the other common leading-out pin of the inner ring coils, a first leading-out pin positioning hole is formed in the insulating positioning plate, and one common leading-out pin of the inner ring coils and the other common leading-out pin of the inner ring coils respectively penetrate through the corresponding first leading-out pin positioning hole downwards.
As a preferred scheme, one end pin of each of the outer ring coils is connected to form one common pin of the outer ring coil, the other end pin of each of the outer ring coils is connected to form the other common pin of the outer ring coil, the insulating positioning plate is provided with a second pin positioning hole, and one common pin of the outer ring coil and the other common pin of the outer ring coil respectively pass through the corresponding second pin positioning holes downwards.
Compared with the prior art, the invention has obvious advantages and beneficial effects, in particular, the technical proposal shows that the invention can effectively utilize the area of the window of the magnetic core, improve the turn ratio of the flat coil, reduce the height of the product and reduce the volume of the product by adopting the combined design of the inside and outside of the vertically wound flat coil for the primary winding and the secondary winding, and has the advantages of simple structure, easier control of product design and production, low cost, higher transmission power and good reliability on the premise of small volume.
In order to more clearly illustrate the structural features and efficacy of the present invention, the present invention will be described in detail below with reference to the accompanying drawings and examples.
Drawings
FIG. 1 is a perspective view of a first embodiment of the present invention;
FIG. 2 is another perspective view of a first embodiment of the present invention;
FIG. 3 is a top view of a first embodiment of the present invention;
fig. 4 is a plan view (combined state inside and outside) of a primary winding and a secondary winding of a second embodiment of the present invention;
fig. 5 is a plan view (exploded state) of a primary winding and a secondary winding of a second embodiment of the present invention;
FIG. 6 is a cross-sectional view of a primary winding and a secondary winding of a second embodiment of the invention;
fig. 7 is a bottom view (physical view) of a primary winding and a secondary winding of a second embodiment of the present invention;
FIG. 8 is a physical diagram of a transformer product according to a second embodiment of the present invention;
fig. 9 is a schematic diagram of transformer application (the number of primary windings of the transformer is N1, and the numbers of secondary windings are N2 and N3, respectively).
The attached drawings are used for identifying and describing: an inner loop coil 10, an outer end lead-out pin 11, an inner end lead-out pin 12, an outer loop coil 20, an inner loop cavity 21, a second flat coil 20', a flat wire 201', a transformer core assembly 30, an E-shaped magnetic core 31, and an insulating positioning plate 40.
Detailed Description
Referring to fig. 1 to 9, specific structures of various embodiments of the present invention are shown.
In the description of the present invention, it should be noted that the azimuth or positional relationship indicated by the terms "upper", "lower", "left", "right", etc. are based on the azimuth or positional relationship shown in the drawings, and are merely for convenience of describing the present invention and simplifying the description, and do not indicate or imply that the apparatus or element referred to must have a specific azimuth, be constructed and operated in a specific azimuth, and thus should not be construed as limiting the present invention.
A high-power transformer of a flat coil type comprises a primary winding, a secondary winding and a transformer magnetic core assembly 30, wherein the primary winding and the secondary winding are sleeved in the transformer magnetic core assembly 30. The transformer core assembly 30 generally includes two oppositely disposed E-shaped cores 31 that are spliced to form a core leg, and the primary winding and the secondary winding are sleeved on the core leg.
Next, the primary winding and the secondary winding are mainly described as adopting an internal and external combined coil design structure.
One of the primary winding and the secondary winding comprises more than two inner coils 10 which are arranged in a vertically stacked mode, and the other one comprises more than two outer coils 20 which are arranged in a vertically stacked mode; each inner loop coil 10 is arranged in the same layer as a corresponding outer loop coil 20, the outer loop coil 20 having an inner loop cavity 21, the inner loop coil 10 being arranged in the inner loop cavity 21 of the outer loop coil 20 and being arranged concentrically with the outer loop coil 20. The leading-out pins of the inner ring coils 10 of different layers are arranged in series or in parallel; the pins of the outer loop coil 20 of the different layers are arranged in series or in parallel.
As shown in fig. 1 to 3, each layer of inner loop coil 10 and outer loop coil 20 is flat, the inner loop coil 10 and/or the outer loop coil 20 is spirally and circumferentially extended from inside to outside by a round wire or a flat wire 2 to form a first flat coil with a coil spiral part positioned on the same horizontal plane, the flat wire flat winding process is mature, the winding is compact, the dimensional accuracy is controllable, the single-side width of the first flat coil is equal to the width of the M times of the round wire or the flat wire, the M is the number of vertical winding turns, and the thickness of the first flat coil is equal to the thickness of the round wire or the flat wire 2. The first flat coils of the inner ring coil 10 and the outer ring coil 20 are positioned on the same horizontal plane, and the first flat coil of the inner ring coil 10 is positioned in the inner ring cavity 21 of the first flat coil of the outer ring coil 20. In this first embodiment, the outer end lead 11 of the inner loop coil 10 is directly bent and extended outwards, while the inner end lead 12 is slightly bent upwards to deviate from the top of the first flat coil of the inner loop coil 10, and then is bent downwards to horizontally extend out of the outer ring of the first flat coil of the inner loop coil 10, and the outer end lead of the inner loop coil 10 can be connected to form a common outer end lead outside the outer ring of the first flat coil of the inner loop coil 10, and likewise, the inner end lead of the inner loop coil 10 can be connected to form a common inner end lead, and the positions of the two are staggered in the circumferential direction, so that the connection is convenient. The four leading-out pins can be positioned on the same side of the magnetic core assembly of the transformer, or can be positioned on different sides in pairs.
In practical design, the inner loop coil 10 and the outer loop coil 20 may be both spirally wound from inside to outside by a round wire, or one may be spirally wound from inside to outside by a round wire, while the other is vertically wound by a flat wire 2 to form a coil spiral part in a shape of being vertically stacked at different heights, which corresponds to a round wire horizontally wound for several turns, and the flat wire 2 is vertically wound for several turns. When in assembly, the inner ring coil 10 is firstly placed, and then the outer ring coil 20 is sleeved on the periphery of the inner ring coil 10, so that the inner ring coil and the outer ring coil are combined and sleeved one by one. Preferably, the leading-out pin 3 of the first flat coil A, which is spirally wound from inside to outside by the round wire, is positioned on one side of the transformer magnetic core assembly, and the leading-out pin 4 of the first flat coil B, which is formed by vertically winding the flat wire, is positioned on the other side of the transformer magnetic core assembly. Because the heights of the first flat coil a and the first flat coil B are inconsistent, the total number of overlapping upper and lower sleeves of the first flat coil a and the first flat coil B can be different in the same winding height (also can refer to the height of the middle column of the magnetic core or can be smaller than the winding in the height range of the middle column of the magnetic core).
The inner and outer combined flat coil has novel design, simple structure, low cost and good reliability; when the transformer is assembled, two flat coils with different sizes are combined internally and externally, the area of a magnetic core window is effectively utilized, the number of turns of the coils is more on the premise of small size, the leading-out pins of the internal coil and the external coil can be connected in series or in parallel, and the transformer design with multiple turn ratios or multiple outputs is realized. The inner and outer combined type flat coil has the advantages of low automatic production cost, high working efficiency, easier control of product design, production and manufacture, better performance, small volume and better cost advantage, and simultaneously has higher transmission power, thereby meeting the requirements of small size and high power.
In the specific structure of the second embodiment, the basic structure of the second embodiment is the same as that of the first embodiment, and the design concept of combining the inside and outside of the second embodiment by adopting two flat coils with different sizes is mainly different from that of the first embodiment: referring to fig. 4 to 7, the inner loop coil 10 and/or the outer loop coil 20 are formed by vertically winding flat wires to form second flat coils with coil spiral parts at different heights, the flat wires are relatively thin, the whole flat coils are still flat after being vertically wound closely, the width of the flat wires 201' is the single-side width of the second flat coils, the thickness of the second flat coils 20' is M times the thickness of the flat wires 201', M is the number of vertical winding turns, the vertical winding process of the flat wires is mature, and the flat coils can be wound tightly and have controllable dimensional accuracy. The second flat coil of the inner loop coil 10 and the second flat coil of the outer loop coil 20 are both uniform or substantially uniform in thickness, and the second flat coil of the inner loop coil 10 is located in the inner loop cavity 21 of the second flat coil of the outer loop coil 20. In the second embodiment, the two end pins of the inner ring coil 10 are respectively located at two ends of the second flat coil of the inner ring coil 10 in the thickness direction, and the two inner end pins are directly bent and extended outwards; the two end leading-out pins of the outer ring coil 20 are also respectively located at two ends of the second flat coil of the outer ring coil 20 in the thickness direction, and the two end leading-out pins are directly bent outwards to extend. One end lead-out pin of the inner ring coil 10 can be connected into a common end lead-out pin, and similarly, the other end lead-out pin of the inner ring coil 10 can be connected into another common lead-out pin, and the two positions are staggered in the circumferential direction, so that wiring is facilitated. The four leading-out pins can be positioned on the same side of the magnetic core assembly of the transformer, or can be positioned on different sides in two or two ways respectively.
Further, as shown in fig. 8, an inner loop coil 10 and an outer loop coil 20 formed by winding a flat wire vertically may be provided on the upper side or the lower side thereof, and the inner loop coil and the outer loop coil may be spirally wound and extended from the inside to the outside of a round wire. And, be provided with insulating locating plate 40 in the bottom of the E-shaped magnetic core 31 of below, be provided with a plurality of pin locating holes on insulating locating plate 40, generally downwards pass corresponding pin locating hole with common pin, the location is convenient, the installation application of the transformer of being convenient for specifically: one end of each of the inner ring coils is connected with one common lead pin of the inner ring coil, the other end of each of the inner ring coils is connected with the other common lead pin of the inner ring coil, a first lead pin positioning hole is formed in the insulating positioning plate, and one common lead pin of the inner ring coil and the other common lead pin of the inner ring coil respectively penetrate through the corresponding first lead pin positioning holes downwards; one end of each of the outer ring coils is connected with one common pin of the outer ring coil, the other end of each of the outer ring coils is connected with the other common pin of the outer ring coil, a second pin positioning hole is formed in the insulating positioning plate, and one common pin of the outer ring coils and the other common pin of the outer ring coils respectively penetrate through the corresponding second pin positioning holes downwards.
The invention mainly adopts the vertical winding flat coil internal and external combined design of the primary winding and the secondary winding, can effectively utilize the area of a magnetic core window, improves the turn ratio of the flat coil, reduces the height of a product and reduces the volume of the product, and meanwhile, has simple structure, easier management and control of product design and production manufacture, low cost and high transmission power on the premise of small volume and good reliability.
The foregoing description is only a preferred embodiment of the present invention, and is not intended to limit the technical scope of the present invention, so any minor modifications, equivalent changes and modifications made to the above embodiments according to the technical principles of the present invention are still within the scope of the technical solutions of the present invention.
Claims (6)
1. A high-power transformer of flat coil class, including primary winding, secondary winding and transformer magnetic core subassembly, its characterized in that:
one of the primary winding and the secondary winding comprises more than two inner ring coils which are arranged in a vertically stacked mode, and the other one of the primary winding and the secondary winding comprises more than two outer ring coils which are arranged in a vertically stacked mode; the inner ring coil and the outer ring coil are respectively formed by vertically winding flat wires to form flat wire flat coils with coil spiral parts at different heights, each inner ring coil and a corresponding outer ring coil are arranged on the same layer, the outer ring coil is provided with an inner ring cavity, and the inner ring coil is arranged in the inner ring cavity of the outer ring coil and is arranged concentrically with the outer ring coil;
and the bottom of the transformer magnetic core assembly is provided with an insulating positioning plate which is used for positioning the leading-out pin of the inner ring coil and the leading-out pin of the outer ring coil.
2. A high power transformer of the pancake coil type according to claim 1, characterized in that: the leading-out pins of the inner loop coils of different layers are arranged in series or in parallel.
3. A high power transformer of the pancake coil type according to claim 1, characterized in that: the leading-out pins of the outer loop coils of different layers are arranged in series or in parallel.
4. A high power transformer of the pancake coil type according to claim 1, characterized in that: the upper side or the downside of the flat wire flat coil is provided with a round wire flat coil, the round wire flat coil is spirally and circularly arranged from inside to outside by a round wire, and coil spiral parts of the round wire flat coil are positioned on the same horizontal plane.
5. A high power transformer of the pancake coil type according to claim 1, characterized in that: one end leading-out pin of a plurality of inner ring coils is connected into one common leading-out pin of the inner ring coils, the other end leading-out pin of a plurality of inner ring coils is connected into the other common leading-out pin of the inner ring coils, a first leading-out pin positioning hole is arranged on the insulating positioning plate, and one common leading-out pin of the inner ring coils and the other common leading-out pin of the inner ring coils respectively penetrate through the corresponding first leading-out pin positioning holes downwards.
6. A high power transformer of the pancake coil type according to claim 1, characterized in that: one end of each of the outer ring coils is connected with one common pin of the outer ring coil, the other end of each of the outer ring coils is connected with the other common pin of the outer ring coil, a second pin positioning hole is formed in the insulating positioning plate, and one common pin of the outer ring coils and the other common pin of the outer ring coils respectively penetrate through the corresponding second pin positioning holes downwards.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310234817.4A CN116110697A (en) | 2023-03-10 | 2023-03-10 | Flat coil type high-power transformer |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310234817.4A CN116110697A (en) | 2023-03-10 | 2023-03-10 | Flat coil type high-power transformer |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN116110697A true CN116110697A (en) | 2023-05-12 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202310234817.4A Pending CN116110697A (en) | 2023-03-10 | 2023-03-10 | Flat coil type high-power transformer |
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| Country | Link |
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| CN (1) | CN116110697A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN118694110A (en) * | 2024-07-26 | 2024-09-24 | 小米汽车科技有限公司 | Coil winding manufacturing method, coil winding, stator assembly, axial flux motor and vehicle |
-
2023
- 2023-03-10 CN CN202310234817.4A patent/CN116110697A/en active Pending
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN118694110A (en) * | 2024-07-26 | 2024-09-24 | 小米汽车科技有限公司 | Coil winding manufacturing method, coil winding, stator assembly, axial flux motor and vehicle |
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