CN203277035U - Transformer without air gap - Google Patents
Transformer without air gap Download PDFInfo
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- CN203277035U CN203277035U CN 201320187904 CN201320187904U CN203277035U CN 203277035 U CN203277035 U CN 203277035U CN 201320187904 CN201320187904 CN 201320187904 CN 201320187904 U CN201320187904 U CN 201320187904U CN 203277035 U CN203277035 U CN 203277035U
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- magnetic core
- magnetic
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- oxide layer
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Abstract
The utility model discloses a transformer without an air gap. The transformer comprises a magnetic core and a coil. The magnetic core at least comprises two magnetic core single bodies. Each magnetic core single body at least comprises one contact face making contact with other magnetic core single bodies. The transformer is characterized in that at least one magnetic core single body comprises a gap layer formed through curtain coating and sintering and used as the contact face, the gap layer comprises a weak magnetism oxide layer, the magnetic core single bodies and a framework with the coil are fixed, or the coil is directly wound around one magnetic core single body and then directly fixed with other magnetic core single bodies. Compared with the prior art, the transformer can achieve gaps, of all kinds of dimensions, among magnetic cores, and is stable in inductance valve, little in loss, high in reliability and easy to produce in a mass mode.
Description
Technical field
The utility model relates to transformer, especially without the transformer of air-gap.
Background technology
In a lot of power-type magnetic elements, for example flyback transformer, saturated in order to prevent magnetic material, namely along with the increase of added electric current, magnetic field intensity can increase thereupon, do not have the magnetic flux density of the magnetic device of air gap to increase very fast, reach the saturation induction density value of magnetic material, in this process, it is very fast that the magnetic permeability of device descends, be that inductance value decline is very fast, lost the function of transformer, can cause simultaneously afunction or the damage of other components and parts.
Prevent that the saturated method of transformer can be by increasing the gap of air gap or weak magnetic material.In the situation that other factors is all identical, air gap or very large on inductance value and saturation characteristic impact by the gap of weak magnetic material, when air gap or gap were large, inductance value was little, and saturation characteristic is good; Air gap or gap hour, inductance value increases, the saturation characteristic variation.
A kind of common method is to obtain air gap by the center pillar of processing magnetic core, as the EE magnetic core.The magnetic core of this method needs secondary operations, easily damages magnetic core, is difficult to simultaneously guarantee higher dimensional requirement.Air gap is large and hour, and there are a lot of problems in the method that the center pillar of processing magnetic core obtains air gap.For large-sized air gap, easily cause leakage field large, thereby make the loss of product under high frequency large; For undersized air gap, tens microns for example, this kind method is difficult for realizing.Another kind of common method is by forming the gap at weak magnetic materials such as the contact-making surface pad adhesive tape of magnetic core, ceramic wafers.The material such as adhesive tape and porcelain plate all needs secondary operations, has increased the production process of adhesive tape and porcelain plate, and the operation of assembling is also cumbersome, spends more human and material resources.Work under the regional condition of high temperature of leakage field when organic materials such as adhesive tapes, material character (thickness that comprises material) varies with temperature and changes, on larger impact is electrically arranged; The long-term work meeting is obviously aging, distortion along with the increase of time, and what have even comes off.Obtain the air gap method with processing magnetic core center pillar the same, be difficult to produce larger and more closely spaced transformer in the contact-making surface pad adhesive tape of magnetic core, the method for ceramic wafer.
The utility model content
Technical problem to be solved in the utility model is, a kind of transformer without air-gap is provided, and makes the inductance value of transformer stable, and loss is little, and reliability is high, is easy to batch production.
Technical problem of the present utility model is solved by following technological means:
A kind of transformer without air-gap comprises magnetic core and coil, and described magnetic core comprises at least two magnetic core monomers, and each magnetic core monomer comprises a contact-making surface that contacts with other magnetic core monomers at least, it is characterized in that:
Comprise the clearance layer as contact-making surface that forms by curtain coating, co-sintering at least one described magnetic core monomer, described clearance layer comprises weak magnetic oxide layer; Described magnetic core monomer with fix with the skeleton of coil, directly fix with other magnetic cores after perhaps described coil directly is wound on a magnetic core monomer.
Preferably:
Described clearance layer comprises and replaces stacked weak magnetic oxide layer and magnetic material layer.
The thickness of every layer of described weak magnetic oxide layer is between 6 μ m to 200 μ m.
Compared with prior art, the beneficial effects of the utility model are: make the non-ferromagnetic material layer by curtain coating on the contact-making surface of magnetic core, sintering, can realize the gap of the various sizes between magnetic core, produce the power transformer product of different induction value, especially the little transformer in the irrealizable gap of conventional method, the method can easily realize below single gap 200 μ m, especially below 100 μ m, and the gap of minimum 6 μ m.
In preferred version, the air gaps that can realize for conventional method or the transformer in gap, the magnetic material that mutually replaces that curtain coating of the present utility model is made and the structure of weak magnetic material layer, can obviously reduce the loss of transformer, thereby the temperature rise that produces when reducing work has increased the efficient of transformer when circuit working.It is stable that the product that the method is produced has inductance value, and reliability is high, and production process is simple, saves the production time.Especially in the power transformer product of EI and UUI type, has advantages of especially easy automation.
Description of drawings
Fig. 1 is the magnetic core schematic diagram of the weak magnetic oxide layer of an individual layer of the utility model specific embodiment;
Fig. 2 is the assembled part schematic diagram of the transformer of the weak magnetic oxide layer of an individual layer of the utility model specific embodiment;
Fig. 3 is a magnetic oxide layer of the utility model specific embodiment and the magnetic core schematic diagram of weak magnetic oxide layer multi-layer cross structure;
Fig. 4 is the schematic diagram of assembled part of the transformer of a magnetic oxide layer of the utility model specific embodiment and weak magnetic oxide layer multi-layer cross structure;
Fig. 5 is the assembled part schematic diagram of the transformer of of the utility model specific embodiment weak magnetic oxide layer of individual layer that reduces magnetic material contact-making surface distance.
Embodiment
Preferred embodiment the utility model is described in further detail for the below's contrast accompanying drawing and combination.
The magnetic core of the present embodiment comprises magnetic core, coil, glue or steel clamp, insulating tape and/or the skeleton of transformer, and magnetic core comprises two magnetic core monomers at least, and each magnetic core monomer comprises a contact-making surface that contacts with other magnetic core monomers at least.Between the magnetic core monomer, fixing by glue, adhesive tape or steel clamp etc. between magnetic core monomer and skeleton.Between coil, there is the adhesive tape insulation outside of outermost layer coil and magnetic core.For some transformer low to requirement of withstand voltage, coil also can directly be wound on magnetic core, and the insulating tape between coil also needn't use.
The preparation of the transformer of the present embodiment comprises the steps:
S1: the magnet idiosome that the magnetic material curtain coating is formed at least one magnetic core monomer.
S2: on a surface of at least one described magnet idiosome, the weak magnetic oxide layer of curtain coating one deck is to form the clearance layer idiosome or on a surface of at least one described magnet idiosome, alternately the weak magnetic oxide layer of curtain coating and magnetic material layer to be forming described clearance layer idiosome, and both are respectively used to form with the magnetic core of magnetic oxide layer a little less than individual layer as the clearance layer of the magnetic core of clearance layer and multi-layer intercrossed structure.
S3: the product of sintering step S2 obtains magnet and the integrated magnetic core monomer of clearance layer, this magnetic core monomer with described clearance layer as contact-making surface;
S4: with described magnetic core monomer with fix with the skeleton of coil, perhaps coil directly is wound on the magnetic core monomer and fixes with other magnetic core monomer.
Then carry out other operations of transformer production, for example, transformer impregnation and baking, test etc.
Wherein the material of weak magnetic oxide layer comprises in mass ratio: Fe
2O
330-70%, ZnO10-30% and CuO1-10%, the relative permeability value scope after sintering is 1 ~ 5.
As shown in Figure 1, be the schematic diagram with magnetic core monomer 10 of the weak magnetic oxide layer of individual layer, magnet 11 is magnetic materials, for example nickel-zinc ferrite.Weak magnetic oxide layer 12 is Fe
2O
3, the compositions such as ZnO, CuO.Whole magnetic core can pass through thick-layer magnetic material 11 of curtain coating, and then magnetic oxide layer 12 a little less than surperficial curtain coating, then be placed on sintering in sintering furnace to magnetic core and obtain.The thickness in monolayer of the weak magnetic oxide layer 12 that makes by casting method between 6 ~ 200 μ m, between preferred 6-100 μ m, the thickness when 12 hour, its tolerance can be accomplished in 1 micron.It is easy that this dimensional accuracy obtains dimensional accuracy than conventional cores processing, and this is very important concerning the transformer that needs big inductance quantity.And the thickness that can make on the existing technique of the Thickness Ratio of the weak magnetic oxide layer 12 that needs hour, can regulate near the weak magnetic material of air by relative permeability, at this moment 12 thickness just can increase, and makes it may reach the level of processing of present production.
As shown in Figure 2, be to have the magnetic core monomer 10 of transformer of the weak magnetic oxide layer of individual layer and the assembling partial schematic diagram of another one magnetic core monomer 30.Weak magnetic material 12 is bonding by glue 40 and other magnetic core monomer 30.The gap of this magnetic device can think that weak magnetic material 12 and glue 40 form.When the thickness of the Thickness Ratio glue of material 12 was much larger, the thickness in gap can think to be exactly 12 thickness; When the thickness of the thickness of material 12 and glue was more or less the same, the thickness of glue will be very large on the impact of device, need to conscientiously control the thickness of glue.Relatively traditional pass through the method that pad adhesive tape and porcelain plate obtain air gap, use the element manufacturing flow process of this method fairly simple.If by the steel clamp fixed magnetic core, the gap of magnetic core is exactly mainly the thickness of weak magnetic material 12.
As shown in Figure 3, be the schematic diagram of the magnetic core 20 of a magnetic oxide layer of the present utility model and weak magnetic oxide layer multi-layer cross structure.At surperficial curtain coating one deck weak magnetic material 22-1 of magnetic core monomer 21, then at 22-1 surface curtain coating magnetic material 23-1, what the material of 23-1 can be with magnet 21 is identical.And then at surperficial curtain coating weak magnetic material, then curtain coating magnetic material.22 and 23 structures constantly repeat, and are 22-N or 23-N on the surface of magnet 21 at last.The magnetic oxide layer on magnet 21 surfaces and the sandwich that weak magnetic oxide layer repeats have so just been formed.With respect to the device of centralized than air gaps, when propagated in sandwich in magnetic field, the transmission range of each non-ferromagnetic material layer was little, leaked into airborne magnetic field ratio little, and little on device impact on every side, the loss of energy is little.
The schematic diagram of assembled part of magnetic device of the magnetic core of transformer of a magnetic oxide layer of the present utility model and weak magnetic oxide layer multi-layer cross structure as shown in Figure 4.The superficial layer 22-N of magnetic core 20 or the surface of 23-N and 30 are bonding by glue 40.
Fig. 5 is the assembled part schematic diagram of the transformer of a weak magnetic oxide layer of individual layer that reduces magnetic material contact-making surface gap.In order to obtain larger inductance value, preferably need the contact-making surface of several magnetic core monomers that very high flatness is arranged, must reduce the impact of the thickness of the bonding glue of contact-making surface simultaneously.Can be at two grooves 40 of side opening of the contact-making surface of magnetic core monomer, after a few part magnetic cores are closely fixed, then place glue 40 li of grooves, between magnetic core, major part is exactly directly contact like this, part magnetic core contact-making surface only has very little air gap, so just can reduce glue thickness to electrical impact.In like manner, for the magnetic device of sandwich, also can process by similar method.A few part magnetic cores fixedly the time, contact-making surface does not just have the impact of glue with steel clamp, and most contact-making surfaces are also direct contacts.
Above content is in conjunction with concrete preferred implementation further detailed description of the utility model, can not assert that concrete enforcement of the present utility model is confined to these explanations.For the utility model person of ordinary skill in the field; without departing from the concept of the premise utility; can also make some being equal to substitutes or obvious modification, and performance or purposes identical, all should be considered as belonging to protection range of the present utility model.
Claims (3)
1. the transformer without air-gap, comprise magnetic core and coil, and described magnetic core comprises at least two magnetic core monomers, and each magnetic core monomer comprises a contact-making surface that contacts with other magnetic core monomers at least, it is characterized in that:
Comprise the clearance layer as contact-making surface that forms by curtain coating, co-sintering at least one described magnetic core monomer, described clearance layer comprises weak magnetic oxide layer; Described magnetic core monomer with fix with the skeleton of coil, directly fix with other magnetic cores after perhaps described coil directly is wound on a magnetic core monomer.
2. the transformer without air-gap according to claim 1 is characterized in that:
Described clearance layer comprises and replaces stacked weak magnetic oxide layer and magnetic material layer.
3. the transformer without air-gap according to claim 1 and 2 is characterized in that: the thickness of every layer of described weak magnetic oxide layer is between 6 μ m to 200 μ m.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 201320187904 CN203277035U (en) | 2013-04-15 | 2013-04-15 | Transformer without air gap |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 201320187904 CN203277035U (en) | 2013-04-15 | 2013-04-15 | Transformer without air gap |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN203277035U true CN203277035U (en) | 2013-11-06 |
Family
ID=49507395
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN 201320187904 Withdrawn - After Issue CN203277035U (en) | 2013-04-15 | 2013-04-15 | Transformer without air gap |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN203277035U (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103198918A (en) * | 2013-04-15 | 2013-07-10 | 深圳顺络电子股份有限公司 | Transformer without air gaps and method for manufacturing transformer |
| CN115579219A (en) * | 2022-11-10 | 2023-01-06 | 广东光达电气股份有限公司 | Variable inductance reactor and preparation method thereof |
-
2013
- 2013-04-15 CN CN 201320187904 patent/CN203277035U/en not_active Withdrawn - After Issue
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103198918A (en) * | 2013-04-15 | 2013-07-10 | 深圳顺络电子股份有限公司 | Transformer without air gaps and method for manufacturing transformer |
| CN103198918B (en) * | 2013-04-15 | 2016-04-20 | 深圳顺络电子股份有限公司 | A kind of transformer without air-gap and manufacture method thereof |
| CN115579219A (en) * | 2022-11-10 | 2023-01-06 | 广东光达电气股份有限公司 | Variable inductance reactor and preparation method thereof |
| CN115579219B (en) * | 2022-11-10 | 2023-09-15 | 广东光达电气股份有限公司 | Variable inductance reactor and preparation method thereof |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| C14 | Grant of patent or utility model | ||
| GR01 | Patent grant | ||
| AV01 | Patent right actively abandoned |
Granted publication date: 20131106 Effective date of abandoning: 20160420 |
|
| AV01 | Patent right actively abandoned |
Granted publication date: 20131106 Effective date of abandoning: 20160420 |
|
| C25 | Abandonment of patent right or utility model to avoid double patenting |