KR100983516B1 - Transformer with low eddy current and magnetic hysteresis losses and manufacturing method thereof - Google Patents

Abstract

The present invention relates to a medium and high frequency transformer having a low eddy current and a loss of magnetic history, and a manufacturing method thereof, comprising: a medium and high frequency transformer including a core, primary and secondary coils, insulating paper, and insulating material; When the frequency band is less than 400Hz and less than 50KHz, and the transformer is less than 30VA and less than 1000VA, when the maximum output voltage is less than 10,000V, the core is made of amorphous or ferrite, and the insulating paper and the insulating material have a low dielectric constant regardless of the insulation grade. Insulation rate is high, the interlayer insulation thickness of the coil is maintained to more than 1mm and less than 4mm, the insulation distance of the core and the coil is maintained to more than 5mm and less than 10mm, medium and high frequency with low eddy current and magnetic history loss To provide a transformer.

Accordingly, the present invention can minimize electrons induced from the core, coil, insulating paper, and insulating material constituting the transformer by the strong electric and magnetic fields generated by the use of medium and high frequency, and thus the high heat generated inside the transformer and In addition to dielectric breakdown, it minimizes the high heat, condensation, and streamer of condenser-type loads (electrodes and dielectrics), which are reactors for ozone and plasma generators, and sine waves (or resonance) with loads (electrodes and dielectrics). Generating sine waves maximizes transformer efficiency, extending transformer operation and maintenance costs and lifespan.

In addition, if the present invention is applied, it is possible to supply a power supply device suitable for ozone (OZONE) or plasma (PLASMA) industries, etc., in which medium and high frequency transformers are mainly used, at a low price.

Eddy current, hysteresis, medium and high frequency, transformer, insulation paper, insulation thickness, insulation interval, insulation breakdown, creepage discharge, flashover, plasma, ozone, resonance, tuning

Description

Medium and high frequency transformer with low eddy current and loss of magnetic history and its manufacturing method {TRANSFORMER WITH LOW EDDY CURRENT AND MAGNETIC HYSTERESIS LOSSES AND MANUFACTURING METHOD THEREOF}

The present invention relates to a medium- and high-frequency transformer with low eddy current and magnetic history loss, and a method of manufacturing the same. More particularly, high heat generated from an electrode and a dielectric by preventing insulation breakdown of a transformer for an electric apparatus using medium and high frequency. The present invention relates to a medium- and high-frequency transformer with low eddy current and loss of magnetic history to minimize condensation and streamer, and a method of manufacturing the same.

In general, a transformer refers to a kind of electric device that changes the voltage or current value of an alternating current by using electromagnetic induction, and the type thereof is a constant, a number of windings, a type of insulator, a cooling medium, a cooling method, an insulating oil deterioration prevention method, and a use. It varies depending on the back.

In particular, these transformers are mainly composed of core, coil, insulating paper, and insulating material, and according to frequency band, low frequency transformer, medium frequency (60 ~ 1000Hz) or high frequency (1 ~ 200KHz) band using commercial frequency (60Hz) band. It is divided into medium and high frequency transformer.

At this time, the medium, high frequency transformer is a core, coil, insulating paper, and insulating material constituting the transformer by the strong magnetic field generated by applying the medium and high frequency to the transformer, so that the transformer has a lot of electric and magnetic interference The efficiency cannot be maximized. This is because the core, the coil, the insulating paper, and the insulating material all have a certain dielectric constant and insulation rate, and when the electric and magnetic interferences occur, more electrons are released to the outside. For example, in the medium and high frequency bands (400Hz to 50KHz), one cycle is repeated 400 times to 50,000 times per second, so a magnetic field much stronger than the commercial frequency (60Hz) band is formed. The electrons inside the conductor, such as electrodes and electrodes, are subject to electric and magnetic interference due to medium and high frequency. As a result, the electrons in the core, coil, insulating paper, and insulating material of the transformer have higher speed and force. Will move. This causes electrons that must flow only inside the conductor to be displaced into unpredictable parts by too fast speed and force. The dissociated electrons collide with other dissociated electrons in different directions to generate heat (eddy current and hysteresis loss), and flashover and creepage between coil layers, cores and coils when the dielectric material has high dielectric constant and weak insulation state. Will cause a discharge.

If the organic energy consumed by the heat in the transformer itself, the amount of electrons (current) supplied to the load decreases as much as the organic electrons consumed by heat, and the voltage supplied to the load increases by the amount of reduced electrons (current). Loads that are supplied with a small amount of electrons (currents) and high voltages generate high heat over time, and if this persists, the transformer that supplies them also generates more heat and flashes or creepage discharges (corona discharges). And eventually breakdown of the insulation.

Therefore, the design of medium and high frequency transformers should focus on being able to transmit the strong magnetic field inside the transformer and the electromagnetic flow inside the coil to the load without electrical loss.

For this purpose, it is necessary to know the electric and magnetic interference of the medium and high frequency depending on the dielectric constant and insulation rate of the transformer components, that is, core, coil, insulating paper, and insulating material.

For example, the + and-moment components (protons and electrons), which did not react very well in the commercial frequency band, move rapidly in the high frequency band of 400 Hz or higher. Especially, in the coil, electrons flowing inside the conductor use insulating paper having high dielectric constant or insulated state If they are weak, they can break through the interlayer insulating paper and be released out of the coil, or even cause creepage discharges between the coil and the coil, and electrons released outside of the insulating paper collide with other electrons released in various directions to dissipate heat. This is the main cause of the increase in heat in the transformer itself.

Therefore, the core is preferably amorphous (amorphous solid) or ferrite which can reduce eddy current and hysteresis loss due to high magnetic flux density; Insulation paper has a high dielectric constant and exhibits a kind of metallic property at high voltage and medium and high frequencies. Therefore, some electrons inside the insulating paper are organically released to the outside, causing a short circuit and generating a lot of heat. If the dielectric state of the coil interlayer paper is high, flashover or creepage discharge occurs between the coil and the coil, and the insulation breaks out and breaks down or burns out. In the case of insulating materials, they should be selected in a similar category to insulating paper, but their relationship to insulation rate should also be considered.

On the other hand, insulation rate indicates the efficiency of insulation paper or heat-transfer material used to protect the area around the conductive part with non-conductor when electricity is flowed from electric equipment, electric wire, etc. In case of transformer that supplies low voltage, insulation breakdown occurs easily when using insulation paper with low withstand voltage. Insulation paper with high insulation rate should be used. Especially for medium and high frequency transformer used in plasma generator or ozone generator, frequency interference is common frequency transformer. Due to the much greater risk of electrical and magnetic hazards than in the case of S, it must be designed with due consideration.

However, the conventional medium and high frequency transformers have serious problems because they are manufactured in accordance with the design method of insulating paper and insulating material suitable for commercial frequency (60 Hz) without considering any electromagnetic interference caused by medium and high frequency.

That is, in the transformer using high voltage and medium / high frequency, the insulation thickness of the coil is designed to be within 1mm ~ 4mm by simply selecting insulation with high withstand voltage without considering the dielectric constant and insulation state. Even in the case of high voltage of 5000 ~ 10000V, the winding of the secondary coil is designed to be wound on one layer without sectioning.

Therefore, the conventional medium and high frequency transformer has the problems described above, and the efficiency is very low. This low-efficiency transformer has a large amount of electrons which are induced, and thus a small amount of electrons supplied to the load (electrode and dielectric) cannot cause resonance (or tuning) with the load (electrode and dielectric).

The resonance phenomenon occurs when the inductive reactance and the capacitive reactance coincide in the series AC circuit. Inductive reactance has a 90 ° advanced phase angle compared to resistance and capacitive reactance has a 90 ° backward phase angle. The opposite reactance is canceled when their magnitudes match.

Inductive reactance increases with increasing frequency, while capacitive reactance decreases with increasing frequency. This is because the fluidized reactance and the capacitive reactance have opposite characteristics, and as one increases, one decreases so that the 'L' and 'C' values can be coupled to either frequency. Resonance (or tuning) in which the opposite reactances are equal in this manner is called resonance (or tuning), and the AC circuit at this time is called a resonance circuit. The resonant current in the resonant state outputs the current and voltage of the sine wave, and the output of the sine wave has the inherent resonant frequency of the resonant circuit, and this ability provides a full sine wave so that the flywheel effect It is called.

In the medium and high frequency transformer and the condenser type load, the resonance 'phenomenon occurs in which the transformer L' value and the load C 'value coincide by either frequency. At this time, any frequency that leads to a coincidence point is called a resonance frequency. In order for the transformer to achieve optimal efficiency at the load, the transformer 'L' value and the discharge tube 'C' value must reach a certain point by the resonance frequency. To cause 'resonance' (or tuning), the amount of electrons supplied from the transformer to the load must be much higher than before, and the transformer must not cause any problems with electromagnetic interference caused by the 'resonance frequency'. A transformer manufactured by a conventional medium and high frequency transformer design cannot generate resonance (or tuning) with a load. Because the insulating paper and the insulating material have high dielectric constant and weak insulation state, they are subjected to electric and magnetic interference due to the 'resonant frequency', so that the electrons induced outside the transformer increases and the eddy current and hysteresis loss are increased. This is because the amount of electrons decreases sharply.

The present invention was created in view of the above-described problems of the conventional medium and high frequency transformers, and has been created to solve these problems. Through the appropriate selection and design of cores, coils, insulating papers, and insulating materials, which are core components of the transformer, The present invention provides a medium and high frequency transformer with low eddy current and low magnetic history loss, which minimizes electric and magnetic interference from high frequency, thereby preventing high heat and insulation breakdown generated inside the transformer.

Another object of the present invention is to oscillate a sine wave through resonance (or tuning) with a load (electrode and dielectric) to maximize transformer efficiency as well as to minimize high heat, condensation and streamer load. The present invention provides a medium and high frequency transformer with low eddy current and magnetic history loss and a method of manufacturing the same.

Medium and high frequency transformer comprising a core, primary and secondary coils, insulating paper, insulating material applied to the present invention for achieving the above object;

The core is made of amorphous or ferrite when the frequency band is less than 400Hz and less than 50KHz over-range, the transformer capacity is less than 30VA and less than 1000VA, and the maximum output voltage is less than 10,000V.

The insulating paper is low dielectric constant and high dielectric constant and is not pure varnish or oil-impregnated irrespective of the insulation grade and is a pure paper, not synthetic paper.

The insulating material is a low dielectric constant and high dielectric constant epoxy or silicone resin,

The interlayer insulation thickness of the coil is maintained at less than 1mm and less than 4mm depending on the frequency used,

Insulation interval of the core and the coil is characterized in that it is maintained less than 5mm and less than 10mm.

The secondary coil may be sectioned into a first coil and a second coil in series connection form.

When the frequency, the transformer capacity, and the maximum output voltage are all maximum values, the interlayer insulation thickness of the coil may be extended only to 60% of the upper limit of the insulation thickness.

Method for producing a medium-high frequency transformer having a frequency of less than 50Hz and less than 400Hz, less than 30VA and 1000VA, the maximum output voltage 10,000V or less applied to the present invention for achieving the above object; The core for transformer is amorphous or ferrite, and the insulation paper is low dielectric constant and high insulation rate, and is not pure varnish or oil-impregnated regardless of insulation grade and is pure paper, not synthetic paper, and the insulation material has low dielectric constant and high insulation rate. Epoxy resin or silicone, batch structure is external type or internal type, cooling method is natural cooling, winding method is lottery, maximum current limiting method is selected as transformer type or 30% solution type ; A coil interlayer insulation part forming step of cutting the selected insulation paper and forming the first and second coil interlayer insulation parts to maintain an insulation thickness of more than 1 mm and less than 4 mm when the manufacturing conditions are set through the setting step; Forming an insulation thickness between the core and the coil layers after forming the insulation thickness between the first and second coil layers in the coil interlayer insulation portion forming step of less than 5 mm and less than 10 mm; In order to minimize the dielectric constant of the insulating paper while maintaining the insulating gap formed at the core and the coil insulation layer forming step of less than 5mm and less than 10%, which is included in the insulating paper while maintaining the relative humidity of 20% and less than 30% similar to the winter relative humidity. The water removal step of removing the water, and after removing the water of the insulating paper, the coil is formed in the state formed by impregnating the coil molded product by impregnating the epoxy resin or the silicon to test the performance, and assembling the enclosure to commercialize Characterized in that the configuration.

In the coil winding and the interlayer insulation forming step, when the secondary coil maximum output voltage is more than 5,000V and less than 10,000V, it is characterized in that the secondary coil is divided into two or more sections in series connection form.

As described in detail above, the present invention can minimize the electrons induced from the core, coil, insulating paper, insulating material constituting the transformer by the strong electric and magnetic fields generated by the use of medium and high frequency, and thus the transformer In addition to the high heat and insulation breakdown generated inside, it minimizes the high heat, condensation, and streamer of the condenser-type loads (electrode and dielectric), which are the reactors of ozone and plasma generators. In addition, it generates 'resonance (or tuning)' function with electrodes and dielectrics, which are condenser-type loads that could not be supported by conventional transformers, and maximizes transformer efficiency by generating waveforms near sine waves in the transformer itself without any waveform compensation device. This will increase the cost and lifetime of transformer operation and maintenance.

In addition, if the present invention is applied, a power supply device suitable for ozone (OZONE) or plasma (PLASMA) industries, etc., in which medium and high frequency transformers are mainly used, can be supplied to consumers at a low price.

Medium and high frequency transformer comprising a core, primary and secondary coils, insulating paper, insulating material applied to the present invention for achieving the above object;

When the frequency band is less than 400Hz and less than 50KHz, and the transformer capacity is less than 30VA and less than 1000VA, and the maximum output voltage is less than 10,000V, the core is made of amorphous or ferrite.

The insulating paper is low dielectric constant and high dielectric constant and is not pure varnish or oil-impregnated irrespective of the insulation grade and is a pure paper, not synthetic paper.

The insulating material is a low dielectric constant and high dielectric constant epoxy or silicone resin,

The interlayer insulation thickness of the coil is maintained at less than 1mm and less than 4mm depending on the frequency used,

Insulation interval of the core and the coil is characterized in that it is maintained less than 5mm and less than 10mm.

The secondary coil may be sectioned into a first coil and a second coil in series connection form.

When the frequency, the transformer capacity, and the maximum output voltage are all maximum values, the interlayer insulation thickness of the coil may be extended only to 60% of the upper limit of the insulation thickness.

Method for producing a medium and high frequency transformer having a frequency band excluding less than 400Hz 50KHz exceeding range, transformer capacity except less than 30VA 1000VA exceeding the maximum output voltage 10,000V or less applied to achieve the above object; The core for transformer is amorphous or ferrite, and the insulation paper is low dielectric constant and high insulation rate, and is not pure varnish or oil-impregnated regardless of insulation grade and is pure paper, not synthetic paper, and the insulation material has low dielectric constant and high insulation rate. Epoxy resin or silicone, batch structure is external type or internal type, cooling method is natural cooling, winding method is lottery, maximum current limiting method is selected as transformer type or 30% solution type ; A coil interlayer insulation part forming step of cutting the selected insulation paper and forming the first and second coil interlayer insulation parts to maintain an insulation thickness of more than 1 mm and less than 4 mm when the manufacturing conditions are set through the setting step; Forming an insulation thickness between the core and the coil layers after forming the insulation thickness between the first and second coil layers in the coil interlayer insulation portion forming step of less than 5 mm and less than 10 mm; In order to minimize the dielectric constant of the insulating paper while maintaining the insulating gap formed at the core and the coil insulation layer forming step 5 ~ 10mm contained in the insulating paper in the state maintained in excess of 20% and less than 20% similar to the relative humidity in winter A water removal step of removing water, and a coil molded product manufacturing step of manufacturing a coil molded product by impregnating the epoxy resin or the silicon in the state where the coil is formed after removing the water of the insulating paper; After the completion of the coiled molded article to the core to test the performance by assembling the coiled molded article, characterized in that it comprises a step of assembling the enclosure to produce a product.

In the coil winding and interlayer insulation forming step, when the secondary coil maximum output voltage is more than 5,000V and less than 10,000V, it is characterized in that the secondary coil is separated into a series connection form two or more sections.

Hereinafter, the invention will be described in more detail.

1 is an exemplary view showing a structure in which primary coils and secondary coils of a medium and high frequency transformer are disposed according to an embodiment of the present invention.

2 is a view showing an equivalent circuit of a medium and high frequency transformer according to an embodiment of the present invention.

3 is a perspective view of FIG. 1.

Coil forming insulating paper 10, primary side coil 1 wound on the first area of the coil insulating paper 10, and secondary side first coil 20 wound on the second area of the coil insulating paper 10. And a secondary side second coil 30 connected in series with the first coil 20 and wound around a third region of the coil insulating paper 10.

The first coil 20 is continuously connected from the start point 11 to the end point 13 and wound around the second region of the core 10. The second coil 30 is continuously connected from the start point 12 to the end point 14 and wound around the third region of the coil insulating paper 10. Both end points of the linear coil 15 are connected in series by soldering the start point 11 of the first coil 20 and the start point 12 of the second coil 30. The first coil 20 and the second coil 30 are wound after the straight coil 15 is covered with pure paper, which is an insulating paper. An end point 13 of the first coil 20 and an end point 14 of the second coil 30 are connected to a load through a voltage output terminal.

In FIG. 2, a core 2 is formed between the primary side coil 10 and the secondary side first and second coils 20 and 30.

4 is an exemplary view of a molding state in which the primary coil 1 of FIG. 3 and the secondary side first and second coils 20 and 30 are wound and the coil is insulated with epoxy resin or silicon.

FIG. 5 is an assembled perspective view of assembling the coil molded article 3 insulated from the epoxy resin or silicon of FIG. 4 to the core.

The core 2 is separated into first and second cores 2a and 2b. After the hole 5 formed in the center of the coiled product 30 is inserted into the first core 2a, the second core 2b is fitted into the hole 5 formed in the center of the coiled product 3.

The present invention is a medium and high frequency transformer mentioned in the prior art, in particular the frequency 400Hz ~ 50KHz, transformer capacity 30 ~ 1,000VA, the maximum output voltage 1 ~ 10000V characteristics of ozone (OZONE) or plasma (PLASMA) generating equipment, etc. The selection and design of cores, coils, insulating papers and insulating materials have been optimized to suit the transformers used, and can be optimized by applying them to facilities in which neon lamps, high frequency furnaces and other medium and high frequencies are used.

That is, the core 2 used in the present invention is preferably used amorphous or ferrite that can minimize the eddy current and the magnetic history loss.

For example, used in the 60 Hz band Since the magnetic flux density is low when the core 2 is used for medium and high frequency, if the AC waveform is repeated tens of thousands from (+) cycle to (-) cycle in one second, the eddy current and hysteresis loss increase, and the surface temperature of the core is 80 ° C. Will rise.

Therefore, the core 2 to be used in the medium and high frequency transformer has a high magnetic flux density, so that the eddy current and hysteresis loss can be minimized even when the alternating waveform is repeated tens of thousands from (+) cycle to (-) cycle in one second. I ferrite is suitable.

In particular, amorphous is suitable for medium and high frequency transformer because of its excellent magnetic flux, but its size (currently only within 10cm can be manufactured, but it cannot be molded in Korea) It is preferable to use a large and inexpensive ferrite core.

In addition, the thickness and the number of turns (Turn Number) of the coil used in the present invention is variable according to the frequency band, but when the maximum output voltage is 10,000V and the transformer capacity is 1,000VA, approximately the thickness of the primary coil is about 2mm, In the case of having a thickness of about 0.25mm, the number of turns (Turn Number) is preferably about 30 times in the case of the primary coil, approximately 1550 times in the case of the secondary coil is preferably maintained.

The foregoing description of the thickness of the primary and secondary coils is merely exemplary, and the thickness of the primary and secondary coils according to the relationship between the maximum output voltage and the transformer capacity may vary as shown in Table 1 below. Of course.

<Table 1>

Output voltage Transformer capacity (VA) Primary Coil Thickness (mm) Secondary coil thickness (mm)
10,000 V
1,000 2.06 0.29 500 1.45 0.20 100 0.65 0.09
5,000 V
1,000 2.06 0.41 500 1.45 0.29 100 0.65 0.13

(Here, the thickness of the primary coil (1) and secondary coils (20, 30) may be exactly the same as the thickness shown in the table, but there may be a slight deviation)

In particular, when the output voltage of the secondary coil is more than 5000V and less than 10000V, the first coil 20 and the second coil 30 as shown in FIG. 1 to prevent insulation breakdown due to core and coil, coil interlayer flashover or creepage discharge. Sectioning is preferred.

Here, the sectioning is a structure in which the secondary coil is separated in series connection state by the first coil 20 and the second coil 30 as shown in FIG. 1. . In an embodiment of the present invention, the secondary coil is sectioned into two with the first and second coils 20 and 30. For example, when the output voltage of the secondary coil is 0 to 7 KV, the secondary coil is wound into two coils. When the output voltage of the secondary coil is more than 7KV and less than 10KV, it is sectioned into two coils.When the output voltage of the secondary coil is more than 10KV and less than 20KV, it is sectioned into three coils.4 When the output voltage of the secondary coil is more than 20KV and less than 30KV, 4 Can be sectioned into two coils. And if more than 30KV can be sectioned into 5 to 10 coils or less depending on the voltage.

At this time, if the secondary coil is not separated, the voltage burden of the secondary coil is increased. In this case, when the high frequency and the high voltage are applied, the thickness of the insulating paper is thickened by the magnetic interference before and after the coil layer has been sufficiently spaced. Even though a lot of electrons are excited through the insulating paper to the outside, heat is generated from the coils, which causes corona discharge between the coils, thereby degrading the stability of the transformer.

On the other hand, when the secondary coil is separated into the first coil 20 and the second coil 30, the voltage sharing is performed, and thus the above-described phenomenon is suppressed because the voltage to be burdened by the coil is sharply reduced. Will be increased.

In addition, the insulating paper used in the present invention is not varnished or impregnated with water, regardless of the insulation grade, it is preferable that the insulating paper of pure paper, not synthetic paper, is used.

Insulation papers such as Table 2, which were mainly used in conventional transformers, are not only weak in interlayer insulation thickness (0.2-0.3mm) but also have high dielectric constant because most of them are coated with oil or synthetic paper including film materials. .

<Table 2>

Insulation paper Allowable temperature Main insulation material Applicable device Y class 90 ° C Cotton, dog, paper, aniline resin, etc. Low pressure device Class A 105 ℃ Varnish impregnation, oil impregnation,
Kraft paper Transformer E class 120 DEG C Polyurethane, crosslinked polyester resin Large capacity device Class B 130 ℃ Mica, asbestos, glass fiber, etc. used with adhesive, B-Class epoxy resin
Mold Transformer Class F 155 ℃ Compound B class together with class H such as silicone resin, F-Class epoxy resin Mold Transformer
Dry Transformer Class H 180 DEG C Asbestos, Fiberglass, Silicone Rubber, H-Class Epoxy Resin, Nomex Paper Class H Dry Transformer
Mold Transformer Class C More than 180 ℃ Using mica, pottery, glass, etc. alone High temperature
Special equipment

(In this case, the insulation paper is a list of typical ones as an example.

Finally, the insulating material used in the present invention, like the insulating paper described above, is required to have the lowest dielectric constant so that the dielectric constant can be minimized from electromagnetic interference of medium and high frequencies, while the dielectric constant is high.

Examples of such materials include epoxy resins and silicone-based insulating materials. In the past, these materials were not taken into account at all, but they were sealed with insulating oil to prevent them, without knowing exactly the cause of the breakdown. In the invention there is no need to do so. Epoxy resin uses epoxy resin adhesive 1500 manufactured and sold by Semedin, Japan, and product name KE1204 (A­B) manufactured and sold by Shin-Etsu Silicone Co., Ltd., as the silicon insulating material.

The high frequency transformer of the present invention uses an insulating material of silicon series, and the medium frequency transformer uses an insulating material of epoxy resin.

Using the core, coil, insulating paper, and insulating material selected by such conditions, the medium and high frequency transformer according to the present invention is manufactured as follows.

First, when a core, a coil, an insulating paper, and an insulating material meeting the above conditions are selected, the process of checking the conditions of use of the medium and high frequency transformer is performed.

For example, these usage conditions include the power supply, frequency range, power consumption, transformer capacity, primary coil input voltage and current, secondary coil maximum output voltage and current, and sectioning in secondary coil windings. Structure, cooling structure, winding method, and maximum current limiting method.

In this case, the power source used is single-phase / three-phase, 220V / 380V, AC / DC, etc. in most homes, 60Hz, single-phase, 220V is used, industrial use mainly 60Hz, three-phase, 380V.

In addition, when manufacturing an ozone generator or a plasma generator transformer having a frequency range of 400 Hz to 50 KHz, for example, a frequency range, power consumption, and a transformer capacity, the maximum output voltage does not affect the electrodes and the dielectric. It is desirable to design within the range of 10000V and the maximum output current is within 100mA (0.1A), in which case the transformer capacity is composed of the maximum output voltage × maximum output current, so it is calculated as, for example, 1KVA (10000V × 0,1A). Could be.

In the case of primary coil input voltage and current, the maximum output voltage is 10000V, the maximum output current is 0.1A, and the primary coil input voltage is 220V and the input current is assumed to be 60Hz, single phase, 220V. Can be calculated as 4.5A (10000V × 0.1A = 220V × 4.5A).

In addition, since the secondary coil output voltage and current are determined early in the design specification as exemplified above, the 10000V and 0.1A described so far may be considered.

In addition, whether the secondary coil is sectioned is preferable to block the breakdown by unconditionally sectioning as shown in Figure 1 when the maximum output voltage exceeds 5000V.

On the other hand, in the case of the arrangement structure or cooling structure, in the case of the present invention there is almost no heat generation, it is preferable that the external iron type or the iron-type arrangement structure is suitable for ease of operation, it is preferable to use a natural cooling method.

In addition, in the case of the winding method, the lottery method is preferable, because in the case of the single winding method, the electronic circuit (inverter) is composed of electric and magnetic forces due to medium and high frequency, which frequently causes failures.

Furthermore, in the case of the maximum current limiting method, since the strong magnetic flux is generated when the maximum current is not limited, a failure due to electric and magnetic problems is caused not only in the transformer but also in the electronic circuit (inverter). Leakage type or non-liquid type is preferable.

As such, when the conditions for use in manufacturing the medium and high frequency transformer according to the present invention are confirmed, the insulating paper is cut.

The insulating paper cutting process is a process of cutting the insulating paper (low dielectric constant and high dielectric constant) of pure paper, which is not synthetic or impregnated with oil, at regular intervals to fit the core, and the maximum output voltage of the secondary coil is If it exceeds 5000V, the secondary winding should be sectioned, so it is desirable to cut the cross-sectional area of the insulating paper in consideration of the reduction.

When the insulating paper is cut through the above process, the coil winding and the interlayer insulating part are formed.

In this case, as described above, in the case of the primary coil, the coil winding preferably maintains 1 to 4 mm so that the interlayer insulation thickness of the coil matches the frequency range of the electric device, and the coil thickness is about 2 mm. As shown in Fig. 3, a total of 30 turns are wound on four layers of 8, 8, 7, and 7 turns each in the first region of the coil-formed insulating paper 10, and the sum of the interlayer insulating paper thicknesses of the primary coil 1 is the core. It is desirable to be able to fit within the width of (2).

Here, the reason for limiting the insulation thickness between the coil layers to less than 1mm and less than 4mm is to minimize the interference of the corresponding frequency of use and to maintain the voltage fluctuation rate of 2.0% or less set by KS in the rated output, the frequency of the present invention. In the transformer having the range, if the insulation thickness is less than 1mm, the insulation function cannot be performed. If the insulation thickness is over 4mm, the resistance value increases, and the voltage fluctuation rate is more than 2.0%. Most ideal.

However, if the frequency, the transformer capacity, and the maximum output voltage are all at the upper limit, the thickness may be increased by up to 60% of the insulation thickness. It should be limited to below this value because it is generated. Of course, such an interlayer insulation thickness, the thickness of the coil or the number of turns is merely an example, and may vary depending on the frequency or the capacity of the transformer.

At this time, if the frequency range, the transformer capacity, the maximum output voltage rises above the value described above, the interlayer insulation thickness of the coil may be extended to 20% than the respective insulation thickness.

<Table 3>

division standard Insulation Thickness Rise frequency 10 KHz increase 20% increase Transformer capacity 1KVA increase 20% increase Output voltage 1,000 V increase 20% increase

For example, Table 4 below shows the interlayer insulation thickness of the coil according to the frequency. In this case, since the transformer capacity is assumed to be 1KVA (1000VA), if the value is changed, the insulation thickness of the coil is also changed.

<Table 4>

frequency Coil Insulation Thickness (mm) 400 Hz to 1 KHz 1.0 1KHz to 10KHz 1.0 to 2.0 10KHz to 20KHz 2.0 to 2.5 20KHz ~ 30KHz 2.5 to 3.0 30KHz to 40KHz 3.0 to 3.5 40KHz ~ 50KHz 3.5 to 4.0

In addition, in the case of the secondary coil, the interlayer insulation thickness is set based on Table 4, and the thickness thereof is set to about 0.25 mm, and as shown in FIG. 3, the first region and the second region of the coil-formed insulating paper 10. The first coil 20 and the second coil 30 in the region is preferably such that 1550 turns are wound around a total of eight layers, each of 194,194,194,193 turns.

In this case, when the maximum output voltage of the secondary coil exceeds 5000V, it is preferable to make the secondary coil sectioned and wound, and in this case, it may vary depending on the frequency, transformer capacity, etc. as in the primary coil 1. Will do.

After the process of forming the coil winding and the interlayer insulation through the above process is completed, the process of forming the core (2) and the coil interlayer insulation (insulation gap).

Here, the insulation interval between the core 2 and the coil layer is preferably more than 5mm and less than 10mm, and of course, can vary according to the transformer capacity change.

At this time, the reason for limiting the insulation interval to more than 5mm, less than 10mm is that when the insulation interval is less than 5mm can not prevent the collision between the core magnetic flux and the coil induced electrons, as well as the high temperature generation of the insulation breakdown, induced more than 10mm Since the insulation function is not improved and only the insulation thickness is increased, the above limit is ideal in terms of the stability and efficiency of the transformer.

Such an insulation gap between the core 2 and the coil layer can be easily confirmed by pre-assembling the core 2 and the coiled molded product 3 while the primary and secondary coils are wound and the insulation part is completed. It is more desirable to maintain the interlayer insulation space accurately using measurement equipment such as gauges. The pre-assembly of the core 2 and the coiled molded product 3 is performed by inserting a hole 5 formed in the center of the coiled molded product 3 into the first core 2a and then forming a hole formed in the center of the coiled molded product 3. The second core 2b is inserted into 5).

At this time, the electronic circuit (inverter) that can supply the medium and high frequency to the input side of the transformer in the state that the core (2) and the coiled molded product (3) is temporarily assembled, and the output side by connecting the electrical equipment to the performance of the output waveform, etc. You can also test

In this way, when the insulation gap between the core 2 and the coil layer is finally secured, the first coil 1 and the secondary coil 1 formed as shown in FIG. After the coil and the second coil (20, 30) is inserted into the molding die and is impregnated with epoxy resin or silicon.

Here, the removal of the moisture absorbed in the insulating paper is to minimize even the dielectric constant that can rise due to this moisture, it is possible to evaporate the moisture through the heating means, the best method is the medium and high frequency according to the present invention The transformer manufacturing space is always kept at an environment of 20-30%, similar to the relative humidity in winter. When the first coil (1) and the second coil (20, 30) of the secondary coil (20, 30) formed as shown in Figure 3 is inserted into the molding mold and then impregnated and cured, the coil molded article as shown in FIG. ) Is formed.

The insulating material such as epoxy resin or silicon may be impregnated in a state where the first and second coils 20 and 30 of the primary side coil 1 and the secondary side coil are formed. At this time, the reason for limiting the time is at least 4 hours or more sufficient impregnation is made, if more than 48 hours impregnation efficiency does not increase this range is appropriate.

In this case, as described above, the moisture of the insulating paper is preferably maintained at less than 20% and less than 30% similar to the relative humidity in winter.

Through this process, when the impregnation of epoxy resin or silicon is completed, the transformer is finally completed by performing a performance test and casing process of making an enclosure to be used as a transformer.

The epoxy resin 1500 manufactured by Semedin Japan and the product name KE1204 (AB) manufactured by Shin-Etsu Silicone Co., Ltd. showed low dielectric constant and high insulation. In the present invention, a coil molded article in which primary coils 10 and secondary coils 20 and 30 are wound is manufactured using epoxy resin or silicon having a low dielectric constant and high insulation. If you do not use the epoxy resin manufactured and sold by Japan's Semedin Co., Ltd., or the product name KE1204 (AB) manufactured by Shin-Etsu Silicone Co., Ltd. The induced electrons are emitted and transferred to the core 2, which causes a problem that the high-frequency transformer is broken. The epoxy resin 1500 is used in the medium and low frequency transformer, and the product name KE1204 (A­B) manufactured by Shin-Etsu Silicone Co., Ltd. is applied to the high frequency transformer.

Here, in the formation of the primary and secondary coil windings and the insulation portion and the epoxy or silicon impregnation process, the reason why the humidity of 20% or more and less than 30% similar to the winter relative humidity is maintained is that the insulating paper and the insulating material have a constant dielectric constant. Because of the high frequency effects, the moisture in the insulation paper and inside the insulation material further increases the dielectric constant, sometimes causing the breakdown of the insulation, because the water with a constant dielectric constant is heated by the frequency of several MHz that the microwave emits. Watching the loss will make it easier to understand.

The medium- and high-frequency transformer according to the present invention manufactured in this way is composed of a core, a coil, an insulating paper, and an insulating material selected according to the use conditions. In particular, the insulation thickness between the coil layers is 1-4 mm, and the gap between the core and the coil is more than 5 mm. Main feature is to keep less than 10mm.

In addition, when the maximum output voltage of the secondary coil exceeds 5000V, it is also a major feature in the configuration that the secondary coil is sectioned by winding two or more.

[Example]

Hereinafter, embodiments according to the present invention will be described.

In order to confirm the characteristics of the medium and high frequency transformer according to the present invention, the transformer was manufactured according to the present invention with the conditions as shown in Table 3.

In this case, the conventional example is a case of a transformer that is conventionally used, and the comparative example is a part of the change of conditions in order to prepare for the present invention.

<Table 5>

division frequency Insulation paper
Kinds coil
Interlayer
Insulation thickness Transformers
Volume Core and
Between coils
Insulation interval Secondary coil
maximum
Output voltage Conventional example 60 Hz Class H 0.2mm 1KVA 1 mm 2000 V Inventive Example 10KHz Class A 2.0mm 1KVA 10 mm 2000 V Comparative example 10KHz Class A 0.8mm 1KVA 2 mm 2000 V

Using transformers manufactured under the same conditions as in Table 5, the characteristics of these transformers, such as heat generation, no-load power loss, corona discharge, and the occurrence of flashover, are shown in Table 6 below.

<Table 6>

division Calorific value No-load power loss Corona discharge Flashover occurrence Conventional example 100 ℃ 850 mA Occur Occur Inventive Example 18 ℃ 20 mA none none Comparative example 90 ° C 100 mA Occur Occur

As shown in Table 6, in the case of the conventional example it was confirmed that it can not be used as a medium-high frequency transformer due to the heat generation, no-load power loss, insulation breakdown (corona discharge generation, flashover occurrence), in the case of the comparative example eddy current and magnetic history Although the loss is greatly reduced, the heat generation is still high and insulation breakdown occurs due to corona discharge and flashover, which is not suitable for medium and high frequency transformers. However, the invention according to the present invention generates little heat (at room temperature). No-load power loss is minimal, and since there is no corona discharge or flashover occurrence, insulation breakdown can be completely prevented, so it is very suitable for medium and high frequency transformer mainly used in ozone generator or plasma generator. Also found very high.

1 is an exemplary view of a structure in which a primary coil and a secondary coil of a high frequency transformer of the present invention are disposed

2 is a structural diagram of an equivalent circuit of a medium and high frequency transformer of the present invention.

3 is a perspective view of FIG.

4 is an exemplary view of a molding state in which the primary coil and the secondary coils of the first and second coils of FIG. 3 are wound and the coils are insulated with epoxy resin or silicon.

5 is an assembled perspective view of assembling a coil molded product insulated from a coil with epoxy resin or silicon of FIG. 4 to a core;

* Explanation of symbols for the main parts of the drawings

1: Primary side coil 2: Core

3: coil forming foam 5: hole

10: insulating paper 20: secondary side primary coil

30: secondary secondary coil

Claims (5)

Core, a primary coil and a secondary coil wound around the core, insulating paper for insulating each coil layer of the primary coil and the secondary coil, and an insulating material surrounding the core, the primary coil and the secondary coil In the transformer comprising: The core is made of amorphous or ferrite, The insulating paper is low dielectric constant and high dielectric constant, and is not pure varnish or oil-impregnated irrespective of insulation grade and is a pure paper, not synthetic paper. The insulating material is an epoxy resin or a silicone resin having a low dielectric constant and a high dielectric constant, The interlayer insulation thickness of the coil is maintained at less than 1mm and less than 4mm depending on the frequency used, The insulation gap between the core and the coil is maintained at less than 5mm and less than 10mm. The transformer of claim 1, wherein the secondary coil is sectioned into a first coil and a second coil in series connection form when the maximum output voltage is greater than 5,000V and less than 10,000V. delete Core, a primary coil and a secondary coil wound around the core, insulating paper for insulating each coil layer of the primary coil and the secondary coil, and an insulating material surrounding the core, the primary coil and the secondary coil In the manufacturing method of a transformer comprising: Forming a coil winding and an interlayer insulator by using insulation paper to form an interlayer insulation part of each of the primary coil and the secondary coil so as to maintain an insulation thickness of less than 1 mm and less than 4 mm according to a use frequency; Forming an insulation interval between the core of the transformer and the primary coil and the secondary coil of less than 5 mm and less than 10 mm; Moisture contained within the insulating paper while maintaining the humidity between 20% and less than 30% to minimize the dielectric constant of the insulating paper while maintaining the insulating gap formed in the core and coil insulation portion forming step less than 5mm and less than 10mm. Removing water to remove the step; And And a coil molded article manufacturing step of manufacturing a coil molded article by removing moisture of the insulating paper and impregnating the insulating material for more than 4 hours and less than 48 hours. The core is amorphous or ferrite, and the insulating paper is low dielectric constant and high dielectric constant and is not pure varnish or oil-impregnated irrespective of the insulation grade, but is a pure paper instead of synthetic paper. Method for producing a transformer, characterized in that the resin or silicone resin. delete

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