CN102360858B - Annular iron core transformer and production method thereof - Google Patents
Annular iron core transformer and production method thereof Download PDFInfo
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- CN102360858B CN102360858B CN 201110330047 CN201110330047A CN102360858B CN 102360858 B CN102360858 B CN 102360858B CN 201110330047 CN201110330047 CN 201110330047 CN 201110330047 A CN201110330047 A CN 201110330047A CN 102360858 B CN102360858 B CN 102360858B
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Abstract
The invention relates to an annular iron core transformer and a production method thereof. The annular iron core transformer comprises an annular iron core and a primary coil and a secondary coil which wind on the annular iron core sequentially, wherein the annular iron core is a non-closed annular iron core with a gap; an insulating membrane is lined at the gap; an epoxy core is formed at an inner circle of the annular transformer; an epoxy layer is arranged on the bottom surface of the annular transformer, and the bottom surface of the epoxy layer is a plane; the epoxy core and the epoxy layer are integrated; a relative surface of the gap is a plane; the width of the gap is between 0.02 and 0.12 millimeter; a shielding layer is arranged between the primary coil and the secondary coil and coats the surface of the primary coil of the integral transformer; and the shielding layer winds the surface of the primary coil and performs superposition coating in 1/4 width of the shielding layer.
Description
Technical field
The present invention relates to electronics and field of electrical equipment, refer to a kind of annular core transformer and production method especially.
Background technology
What use at present generally is to do high-power transformer with EI type transformer, be that enamelled wire is wound on the skeleton, again silicon steel sheet is inserted on the skeleton and the EI type transformer that forms, EI type transformer structurally, owing to the reason of silicon steel sheet scale, overall volume is big, influence the weight of installing space and the product of product, in the use, because EI type structural reason, so design the time exist iron loss and copper loss greatly, leakage field is big, makes that transformer efficiency is low, temperature rise, noise be big.
Also having a kind of generally is with the iron core toroidal transformer in slit not, be to use the silicon steel sheet winding shaping, wrap insulating barrier again, the ring-shaped transformer that forms around enamelled wire of back, iron core do not crack the crack toroidal transformer structurally, iron core is with the silicon steel sheet winding shaping crack of not cracking, there is not the bag screen between primary winding and the secondary winding, in the use, owing to the iron core crack reason of not cracking, so after the transformer energising, inrush current moment increase.Transformer and external connected electronic components and parts are damaged easily, also have transformer in use because voltage fluctuation makes the transformer magnetic saturation easily, and cause that the transformer heating is up to burning.
Because transformer endoporus and transformer bottom surface are without any processing, institute is so that the out-of-flatness of transformer bottom surface, cause to produce the polyester film insulation that resonance causes total noise of centrifuge and manually moves damage transformer bottom surface in the process between transformer and the installation panel electric shock harm that causes the electric leakage of transformer bottom surface to cause.
Summary of the invention
Purpose of the present invention at first is after solving the transformer energising, the steady and transformer fluctuation of voltage in use of inrush current, and the transformer leakage field is serious, and waveform stabilization does not have burr, spike when transformer voltage is exported in addition.
Another object of the present invention is that solution transformer bottom surface is smooth, makes can not produce resonance, noiseless between transformer and the installation panel and make things convenient for the workman to make the easy for installation and transformer bottom surface damage in handling process and in the use moving process of transformer with Robot actions.
The present invention is achieved by the following technical solutions:
A kind of annular core transformer includes an annular core, is around in primary coil and secondary coil on the annular core successively; Described annular core is for arranging apertured non-closed annular core; Place, described slit is lined with insulation film; The inner circle of described ring-shaped transformer is provided with the epoxy resin core, and the toroidal transformer bottom surface is provided with epoxy resin layer, and the bottom surface of described epoxy resin layer is a plane; Described epoxy resin core and epoxy resin layer are an integral body; Described slit apparent surface is the plane; Described gap width is 0.02-0.12mm; Between described primary coil and the secondary coil screen is arranged; Described polymeric barrier layer materials coats whole transformer surface; Described polymeric barrier layer materials is Copper Foil; Described screen width is identical; Described screen twines on primary coil surface and coats and with 1/4th of the screen width coating that superposes.
As further improvement, the thickness of described Copper Foil is 0.01-0.1mm.
As further improvement, described insulation film is mylar; The width of described insulation film adapts with the slit of annular core.
A kind of production method of annular core transformer includes:
The course of processing of annular core, the course of processing of screen and the casting cycle of epoxy resin.
The course of processing of described annular core comprises:
A will process the selected material of iron core and cut Rack as requested, and this description of materials and width require to adjust according to production performance;
B turns to the iron core of regulation internal diameter and external diameter with the material after the cutting;
C passes through annealing in process with rolled iron core;
D will cool off back iron core dipping lacquer and handle and dry processing;
E will cool off the back iron core and cut the slit with cutting machine; The molybdenum filament cutting is adopted in described cutting;
F serves as a contrast in the annular core with the identical fuse of annular core internal diameter, and the 1mm width is supportted in the annular core slit;
G removes the impurity in the slit, puts into insulation film, and means of spot welds is carried out in circle and upper and lower each 2 of cylindrical slit in iron core.
Described annealing in process was included in the annealing furnace at first in temperature 450-550 ℃ annealing 5 hours, was warmed up to 800-870 ℃ and keep 10 hours then, and then was cooled to cooling below 300 ℃;
Described oven dry is treated to and keeps 150 ℃ of oven dry of temperature 4-5.5 hour in baking oven.
The used lacquer of described dipping lacquer is epoxy resin; Described dipping lacquer is vacuum paint dipping.
The described screen course of processing comprises:
A, Copper Foil is stretching, touch the whole piece Copper Foil with adhesive tape again, tape width is wideer than Copper Foil, and both sides exceed the Copper Foil same widths; At the polyester film of Copper Foil another side subsides with the adhesive tape same widths, adhesive tape and polyester film are pasted together;
B twines coating with the Copper Foil after handling through step a with 1/4th stacks of Copper Foil width, coats transformer.
Described epoxy resin casting cycle comprises:
1), prepares mould and mould soaked into release agent;
2), prepare cold melt epoxy resin, described low temperature refers to be lower than 80 ℃;
3) the epoxy resin 2mm-4mm thickness of casting fusing in mould;
4) treat to carry out second casting behind the epoxy resin cure, reach the bottom thickness of regulation behind the described second casting, and place toroidal transformer, a small amount of casting epoxy resin is placed under the constant temperature and solidifies again;
5), when epoxy resin surface is gel, handle is put into the toroidal transformer circle, adjust the handle height, casting epoxy resin in the circle in toroidal transformer;
6), the demoulding behind the epoxy resin cure for the treatment of to justify in the toroidal transformer.
The invention has the beneficial effects as follows:
1, its efficient height of annular core transformer, temperature rise is low, noise is little.
2, iron core cracks after the energising of crack toroidal transformer, and inrush current moment is steady.Can not cause damage to transformer and external connected electronic components and parts, voltage fluctuation in transformer uses can not make transformer produce magnetic saturation.
3, the waveform that the annular core transformer is exported behind the copper-clad paper tinsel between primary and secondary is level and smooth, no burr.
4, transformer endoporus and transformer bottom surface are irritated epoxy resin and put into handle in the middle of transformer endoporus epoxy resin, make smoothly between transformer and the installation panel can not produce resonance and use Robot actions can make things convenient for the workman to move and install, can not make transformer manually move the polyester film insulation that damages the transformer bottom surface in the process.
Description of drawings
Fig. 1, the cross-sectional view of a kind of annular core transformer of the present invention;
Fig. 2, the annular core schematic diagram of a kind of annular core transformer of the present invention;
1, annular core 1.1, slit 1.2, insulation film 2, primary coil
3, screen Copper Foil 4, secondary coil 5, epoxy resin layer 6, epoxy resin core
7, handle 8, installing hole 8.1, pit
Embodiment
The embodiment of following DETAILED DESCRIPTION The present application, the example of described embodiment is shown in the drawings, wherein identical or similar label is represented identical or similar elements or the element with identical or similar functions from start to finish, be exemplary below by the embodiment that is described with reference to the drawings, only be used for explaining the application, and can not be interpreted as the restriction to the application.
The present invention realizes by following technology, and a kind of annular core transformer includes an annular core 1, is around in primary coil 2 and secondary coil 4 on the annular core 1 successively; Described annular core 1 is for being provided with the non-closed annular core in slit 1.1; Place, described slit is lined with insulation film 1.2; Described slit 1.1 apparent surfaces are the plane, and described gap width is 0.02-0.12mm; The width in slit is selected 0.02mm, 0.05mm, 0.08mm, 0.1mm, slit that 0.12mm is different respectively in various embodiments of the present invention, all can realize purpose of the present invention, and preferred gap width of the present invention is 0.05mm.The inner circle of described ring-shaped transformer is provided with epoxy resin core 6, and the toroidal transformer bottom surface is provided with epoxy resin layer 5, and the bottom surface of described epoxy resin layer 5 is a plane; Described epoxy resin core and epoxy resin layer are an integral body; Have screen 3 to isolate between described primary coil 2 and the secondary coil 4, used in the present embodiment polymeric barrier layer materials is Copper Foil, and described Copper Foil coats whole transformer surface; Described Copper Foil width is in the present embodiment identical, and the specification of Copper Foil is the long 18000mm of wide 15mm x; Described Copper Foil twines on primary coil surface and with 1/4th of the copper sheet width coating that superposes, also can select the Copper Foil of different size in other embodiments of the invention according to different needs for use.In the present embodiment, what insulation film was selected for use is mylar, in other embodiments, also can select other thin-film material for use.
Embodiments of the invention are realized by following program:
The annular core transformer core is made
The annular core transformer core is made, and is placed in the material cutting machine with the Japanese 0.27mm of Nippon Steel material earlier material is slit into the 52mm width, also can require to adjust the width of material and material according to the transformer different performance; With the air pump up-coiler material is being turned to internal diameter 100mm, the iron core of external diameter 177mm, wherein internal diameter can be according to different performance requirement adjustment with external diameter; Again coiling well the back iron core put in the annealing furnace and anneal, selected in 500 ℃ the temperature annealing in the present embodiment for use 5 hours, select for use 450 ℃, 550 ℃ all can realize purpose of the present invention in other embodiments of the invention; Then temperature being raised to 850 ℃ kept 10 hours, be to select for use to be warmed up to 850 ℃ in an embodiment of the present invention, in other embodiments, what select for use is 800 ℃, 820 ℃, 870 ℃ reduce the temperature to cooling below 300 ℃ again, etc. cooled iron core epoxy resin coating vacuum paint dipping, after the iron core drip-dry, again iron core is put into oven for drying, temperature is dried by the fire after 5 hours about 150 ℃, and iron core is taken out cooling, again iron core is put on the wire cutting machine, with the cutting of the molybdenum filament between the diameter 0.02mm-0.12mm, the molybdenum filament according to different slit requirement use different-diameters cuts out a slit to iron core.Select for use in the present embodiment is that the 0.05mm molybdenum filament has cut into the 0.05mm slit.Iron core gravitation after the cutting must be inward, being scattered can not appear in iron core like this, serve as a contrast into bundle of circles iron core slit in the iron core with the 100mm fuse again and overhang 1mm, at the impurity of disposing the inside with air gun, again 0.05mm X 52mm X 38.5mm polyester film is put into the place, slit, the material of lining in the slit can be changed according to the different needs of client, the material size is according to the size adjustment of different iron cores, after having served as a contrast polyester film, interior round fuse is taken away, the slit clamps, again in iron core on circle and the cylindrical slit, following each point two spot welding are lived, and make iron core slit free from flaw, dislocation-free.
Wrap screen between elementary and secondary, earlier that the Copper Foil of wide x 18000 length of 15mm is stretching, width and length can adjust according to the size of transformer, draw adhesive tape to touch the whole piece Copper Foil with 20mm width wheat again, each reserves 2.5mm to tape width more than Copper Foil width both sides, another side at Copper Foil pastes 20mm width polyester film again, each reserves 2.5mm to the polyester film width more than Copper Foil width both sides, make polyester film and wheat draw adhesive tape to paste and allow Copper Foil insulate together, twine coating with the Copper Foil after above-mentioned processing on the primary coil surface, be to coat with 1/4 stack of Copper Foil width when twining, the stack width can be according to the size adjustment of transformer, encase whole transformer, draw at lead-in wire of Copper Foil welding, the position of wire bonds can be adjusted according to the different needs of client.
Epoxy resin is irritated in transformer endoporus and bottom surface, do the frock of an aluminum material earlier, the frock material can be changed according to different needs, the frock size is according to the transformer size and the needs making is installed, again frock is soaked into release agent, again frock is lain on the operating desk after drying, pour into a mould epoxy resin layer 5 again on the frock, thickness is 2mm, thickness can be according to the weight adjustment of transformer, after epoxy resin layer 5 solidifies, casting epoxy resin on the epoxy resin after the curing again, thickness 8mm, thickness can be adjusted according to the transformer different needs, and put into toroidal transformer at once, and add the epoxy resin of trace again, make epoxy resin the same with the frock height, under the temperature between 30 ℃ and 40 ℃ about 2-3 hour again, can adjust the time according to different temperature, when surface gel, circle is put into handle 7 in transformer again, handle 7 exceeds transformer surface 50mm, can adjust length according to different action need, wait epoxy resin cure after, circle casting epoxy resin in transformer again, water till the scale of frock, be epoxy core 6, interior annulus epoxy resins core 6 highly can be according to different installation requirement adjustment, epoxy resin core 6 curing and demolding of circle in waiting again herein.When casting, reserve installing hole 8 and pit 8.1.
The above only is preferred implementation of the present invention; should be pointed out that for the person of ordinary skill of the art, under the prerequisite that does not break away from the application's principle; can also make some improvements and modifications, improvements and modifications also should be considered as the application's protection range like this.
Claims (6)
1. an annular core transformer includes an annular core, is around in primary coil and secondary coil on the annular core successively; Described annular core is for arranging apertured non-closed annular core; Place, described slit is lined with insulation film; It is characterized in that: the inner circle of described toroidal transformer is provided with the epoxy resin core, and the toroidal transformer bottom surface is provided with epoxy resin layer, and the bottom surface of described epoxy resin layer is a plane; Described epoxy resin core and epoxy resin layer are an integral body; Described slit apparent surface is the plane; Described gap width is 0.02-0.12mm; Between described primary coil and the secondary coil screen is arranged; Described polymeric barrier layer materials coats whole transformer surface; Described polymeric barrier layer materials is Copper Foil; Described screen width is identical; Described screen twine to coat and with 1/4th of the screen width coating that superposes at primary coil.
2. annular core transformer according to claim 1, it is characterized in that: the thickness of described Copper Foil is 0.01-0.1mm.
3. annular core transformer according to claim 1, it is characterized in that: described insulation film is mylar; The width of described insulation film adapts with the slit of annular core.
4. an annular core transformer production method is characterized in that: include the course of processing of annular core, the course of processing of screen and the casting cycle of epoxy resin;
The course of processing of described annular core comprises:
A will process the selected material of iron core and cut Rack as requested, and this description of materials and width require to adjust according to production performance;
B turns to the iron core of regulation internal diameter and external diameter with the material after the cutting;
C passes through annealing in process with rolled iron core;
D will cool off back iron core dipping lacquer and handle and dry processing;
E will cool off the back iron core and cut the slit with cutting machine; The molybdenum filament cutting is adopted in described cutting;
F serves as a contrast in the annular core with the identical fuse of annular core internal diameter, and the 1mm width is supportted in the annular core slit;
G removes the impurity in the slit, puts into insulation film, and means of spot welds is carried out in circle and upper and lower each 2 of cylindrical slit in iron core;
The described screen course of processing comprises:
A, Copper Foil is stretching, touch the whole piece Copper Foil with adhesive tape again, tape width is wideer than Copper Foil, and both sides exceed the Copper Foil same widths; At the polyester film of Copper Foil another side subsides with the adhesive tape same widths, adhesive tape and polyester film are pasted together;
B twines coating with the Copper Foil after handling through step a with 1/4th stacks of Copper Foil width, coats transformer;
Described epoxy resin casting cycle comprises:
1), prepares mould and mould soaked into release agent;
2), prepare cold melt epoxy resin, described low temperature refers to be lower than 80 ℃;
3), the epoxy resin 2mm-4mm thickness of casting fusing in mould;
4), treat to carry out second casting behind the epoxy resin cure, reach the bottom thickness of regulation behind the described second casting, and place toroidal transformer, a small amount of casting epoxy resin is placed under the constant temperature and solidifies again;
5), when epoxy resin surface is gel, handle is put into the toroidal transformer circle, adjust the handle height, casting epoxy resin in the circle in toroidal transformer;
6), the demoulding behind the epoxy resin cure for the treatment of to justify in the toroidal transformer.
5. annular core transformer production method according to claim 4, it is characterized in that: described annealing in process is included in the annealing furnace and at first annealed 5 hours in temperature 450-550 ℃, be warmed up to 800-870 ℃ and keep 10 hours then, and then be cooled to cooling below 300 ℃;
Described oven dry is treated to and keeps 150 ℃ of oven dry of temperature 4-5.5 hour in baking oven.
6. annular core transformer production method according to claim 4, it is characterized in that: the used lacquer of described dipping lacquer is epoxy resin; Described dipping lacquer is vacuum paint dipping.
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| Application Number | Priority Date | Filing Date | Title |
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| CN 201110330047 CN102360858B (en) | 2011-10-26 | 2011-10-26 | Annular iron core transformer and production method thereof |
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| Application Number | Priority Date | Filing Date | Title |
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| CN 201110330047 CN102360858B (en) | 2011-10-26 | 2011-10-26 | Annular iron core transformer and production method thereof |
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| CN102360858A CN102360858A (en) | 2012-02-22 |
| CN102360858B true CN102360858B (en) | 2013-07-10 |
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Families Citing this family (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102360861B (en) * | 2011-10-26 | 2013-10-09 | 宁波中策亿特电子有限公司 | Magnetic leakage-preventing annular transformer |
| CN103065772A (en) * | 2013-01-28 | 2013-04-24 | 广东新昇电业科技股份有限公司 | Transformer iron core structure and transformer |
| CN103633852A (en) * | 2013-12-11 | 2014-03-12 | 佛山市欧立电子有限公司 | Power transformation unit |
| TWI576873B (en) * | 2015-11-12 | 2017-04-01 | All Ring Tech Co Ltd | Iron foil on the copper foil method and device |
| CN106024362B (en) * | 2016-08-03 | 2018-02-27 | 重庆金籁科技股份有限公司 | A kind of preparation method of high frequency transformer and its obtained high frequency transformer |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN201562577U (en) * | 2009-12-18 | 2010-08-25 | 平湖市声佳电子有限公司 | Improved structure of annular transformer |
| CN102360861A (en) * | 2011-10-26 | 2012-02-22 | 宁波中策亿特电子有限公司 | Magnetic leakage-preventing annular transformer |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| WO2009008740A1 (en) * | 2007-07-09 | 2009-01-15 | Power Concepts Nz Limited | A transformer |
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Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN201562577U (en) * | 2009-12-18 | 2010-08-25 | 平湖市声佳电子有限公司 | Improved structure of annular transformer |
| CN102360861A (en) * | 2011-10-26 | 2012-02-22 | 宁波中策亿特电子有限公司 | Magnetic leakage-preventing annular transformer |
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