CN100524550C - 低电压复合材料模具 - Google Patents
低电压复合材料模具 Download PDFInfo
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- CN100524550C CN100524550C CNB2004800162000A CN200480016200A CN100524550C CN 100524550 C CN100524550 C CN 100524550C CN B2004800162000 A CNB2004800162000 A CN B2004800162000A CN 200480016200 A CN200480016200 A CN 200480016200A CN 100524550 C CN100524550 C CN 100524550C
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/12—Insulating of windings
- H01F41/125—Other insulating structures; Insulating between coil and core, between different winding sections, around the coil
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/061—Winding flat conductive wires or sheets
- H01F41/063—Winding flat conductive wires or sheets with insulation
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/098—Mandrels; Formers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/32—Insulating of coils, windings, or parts thereof
- H01F27/322—Insulating of coils, windings, or parts thereof the insulation forming channels for circulation of the fluid
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/12—Insulating of windings
- H01F41/127—Encapsulating or impregnating
Abstract
通过在多个环形支撑板上形成复合材料板以形成内层以制造变压器线圈。线圈缠绕在内层上。通过在线圈上卷绕复合材料板形成外层。外层机械地附着到线圈。基座附着到线圈组件以及使用环氧树脂封装线圈。环氧树脂形成与内层和外层的接合,该内层和外层成为变压器线圈的组成部分。
Description
背景技术
本发明通常涉及一种变压器线圈。更尤其是,本发明提供了一种制造具有复合材料内层和外层的封装变压器线圈的方法。
普通转让给Lanoue等人的美国专利号6221297中公开了一种方法来制造嵌入在浇注树脂中的变压器绕组。一次性模具围绕支撑板形成并且用作绕线心轴。该一次性模具是由钢板材料制成的。在缠绕线圈之后,另一块钢板被施加到外部。环氧树脂施加在两块钢板之间并允许固化。然后,去除钢板,留下环氧树脂封装的芯。
发明内容
根据本发明,通过在多个环形支撑板上卷绕复合材料板形成内层而制造变压器线圈。线圈围绕该内层缠绕。通过在线圈上卷绕复合材料板形成外层。通过将该外层机械地附着到线圈上而形成线圈组件,并且基座附着到线圈组件上。在基座和线圈组件之间提供密封,以避免封装过程中环氧树脂泄漏。用环氧树脂填充线圈组件以封装线圈。
根据本发明的另一方面,至少该内层成为变压器线圈的一部分。
根据本发明的另一方面,制造变压器线圈,其具有内层,多个线圈绕组、外层和环氧树脂材料,该环氧树脂材料封装线圈绕组并在线圈绕组和内层之间形成第一接合并在线圈绕组和外层之间形成第二接合。
应当强调的是,当用在该说明书中时,采用术语“包括”以确定所述特征、步骤或者部件的存在,但是并不排除一个或者多个其它特征、步骤、部件或者其组合的存在或者增加。
附图的简要说明
通过阅读下述的具体描述并结合附图将可以理解本发明的目的和优点,其中:
图1是描述在根据本发明的方法制造变压器线圈中将复合材料缠绕到心轴上的透视图;
图2是描述将绝缘带和导体缠绕到内层上以制造变压器线圈的步骤的透视图;
图3是示出了线圈的透视图,该线圈缠绕在内层上,外层施加在线圈上,冷却导管条插在线圈的层之间,以形成制成的线圈组件;
图4是图3中制成的线圈组件的透视图,该线圈组件从绕线机上取下并以竖直位置放置在模制基座上,准备好进行环氧树脂封装;以及
图5是描述在封装线圈并去除图4的冷却导管条之后的线圈和模具组件的透视图。
具体描述
图1描述了具有常规正方形的心轴12的线圈绕线机10。内支撑板14施加到心轴12上。内支撑板14的尺寸和形状确定了成品线圈的尺寸和形状。例如,图1所示的内支撑板14是椭圆形的或者卵形的形状,并可以用于制造具有卵形构造的线圈。内支撑板14可以由任何合适的材料构成,例如11量具钢。内支撑板的数量和排列主要依赖于变压器的尺寸。例如,图1示出了在正方形心轴12上等间距排列的四个内支撑板14。隔离管(未示出)可以安装在内支撑板14之间的心轴12上以保持内支撑板14之间的间隔。可以使用多种长度的隔离管来适应多种线圈轴向长度。可以设置引线支撑板(未示出)以在绕线过程中将起始引线保持在适当的位置。引线支撑板可以放置在心轴12的端部附近,并防止由于绕线机的张力导致引线围绕模具滑动。
复合材料板16卷绕在内支撑板14上。通过支撑板中的狭槽(未示出),复合材料16机械地附着到内支撑板14上。这将复合材料板16锁合到使该板可以紧紧地围绕内支撑板14卷绕的位置,由此消除了卷绕过程中任何的材料滑动。以若干重叠层的形式连续地施加该复合材料16。该复合材料优选是非导电的和柔性的。合适的材料包括玻璃纤维、麦拉(Mylar)、碳纤维和塑料。
复合材料板16形成变压器线圈的内层20并充当用于线圈缠绕过程的心轴基座。用无粘性的玻璃带将卷绕的复合材料板16保持或者固定在适当的位置。将塑料带,例如Mylar带,施加到内层20的整个长度上。该Mylar带密封了内层20,以便于随后进行的环氧树脂封装过程。
在已经完成了内层20之后,将线圈缠绕在内模具上。如图2所示,使用交错的铜导体层24和绝缘带层26在常规绕线机10上缠绕线圈。如图3所示,在缠绕过程中将冷却导管条28插在导体的每隔一层之间以在成品变压器中提供冷却导管。在冷却导管条28被插入到线圈层之间之前,优选用润滑剂例如硅树脂涂覆冷却导管条28,以助于稍后从封装变压器线圈中取出这些冷却导管条28。除了使用冷却导管条28之外,也可以使用提供冷却导管的其它方法,例如在普通转让的美国专利申请号10/026199中所述的那些。
在已经完成了线圈绕组30之后,围绕该线圈绕组卷绕外层34。外层34是由和用于构成内模具20的相同的复合材料构成。以若干重叠层的形式连续地施加复合材料板,用玻璃粘接带将这些重叠层机械地附着到线圈绕组30,以将该板保持在其起始位置。在线圈绕组30上卷绕该复合材料板之后,无粘性玻璃带32螺旋状地卷绕在外层34上,以将它固定在适当的位置。如图3所示,通过在若干位置用捆扎带36捆扎该模具而将该外层34固定。
如图4所示,从绕线机10取下绕线线圈和模具组件38,并将其竖直放置以便安装并连接到模制基座40。设置优选包括螺纹拉杆的机械装置(未示出),用于朝着模制基座40向下对该线圈和模具组件38施加压力,以便对靠着模制基座40的硅橡胶垫圈(未示出)进行压缩,由此避免在封装过程中环氧树脂的泄漏。如图4所示一旦完成了该最终的组件,该组件则准备好来进行环氧树脂封装了。该封装过程优选是制造变压器线圈中使用的常规真空封装过程。
在已经封装了模具和线圈组件38之后,如图5所示,已经去除了图4中的冷却导管条28。去除冷却导管条之后,用于保持外模具34的捆扎带36也被去除了。用于将模具和线圈组件38固定到模制基座40的机械结构被去除,并且从模制基座40取下封装线圈30。
从前述的内容,人们应当理解的是,所公开的方法和所得到的变压器线圈提供了在现有技术基础之上的改进。使用复合材料的内层和外层(它们形成为变压器线圈的组成部分)消除了对本领域公知的钢模具的需求。因此,消除了与使用钢模具有关的材料浪费和劳动力费用。而且,复合材料的内层和外层在高电压线圈和低电压线圈之间提供了增强的电介质绝缘。
现在已经关于一个实施例描述了本发明。考虑到该公开的内容,那些本领域技术人员很容易对本发明作出可替代的实施例。这些和其它可替代的实施例意欲落在随后的权利要求的范围内。
Claims (16)
1、一种制造变压器线圈的的方法,包括步骤:
通过在多个环形支撑板上卷绕非导电和柔性的复合材料板形成内层;
围绕内层缠绕线圈;
通过在线圈上卷绕非导电和柔性的复合材料板形成外层;
将外层机械地附着到线圈,由此形成线圈组件;
将基座附着到线圈组件;
在基座和线圈组件之间提供密封,以阻止封装过程中环氧树脂的泄漏;和
用环氧树脂填充线圈组件以封装该线圈。
2、如权利要求1所述的方法,其中至少该内层成为变压器线圈的一部分。
3、如权利要求1所述的方法,其中该内层和该外层成为变压器线圈的一部分。
4、如权利要求1所述的方法,其中该复合材料包括聚合材料。
5、如权利要求4的方法,其中该复合材料包括玻璃纤维。
6、一种变压器线圈,包括:
多个支撑板;
在支撑板上卷绕的内层;
多个线圈绕组;
外层;和
环氧树脂材料,其封装线圈绕组并在线圈绕组和内层之间形成第一接合,以及在线圈绕组和外层之间形成第二接合;其中
该内层和该外层各自包括非导电和柔性的复合材料。
7、如权利要求6所述的变压器,其中该线圈绕组由导电材料和绝缘材料的交错层形成。
8、如权利要求6所述的变压器,其中每个支撑板都具有环形形状。
9、如权利要求6所述的变压器,其中该复合材料包括聚合材料。
10、如权利要求9所述的变压器,其中该复合材料包括玻璃纤维。
11、如权利要求6所述的变压器,该内层包括在复合材料和线圈绕组之间的密封层。
12、如权利要求6所述的变压器,其中该外层通过重叠多层复合材料板形成。
13、如权利要求6所述的变压器,其中该内层通过重叠多层复合材料板形成。
14、如权利要求1所述的方法,包括在该内层和该线圈之间形成密封层。
15、如权利要求1所述的方法,其中该外层通过重叠多层复合材料板形成。
16、如权利要求1所述的方法,其中该内层通过重叠多层复合材料板形成。
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/459,055 US6930579B2 (en) | 2003-06-11 | 2003-06-11 | Low voltage composite mold |
US10/459,055 | 2003-06-11 |
Publications (2)
Publication Number | Publication Date |
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CN1806303A CN1806303A (zh) | 2006-07-19 |
CN100524550C true CN100524550C (zh) | 2009-08-05 |
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CNB2004800162000A Expired - Fee Related CN100524550C (zh) | 2003-06-11 | 2004-06-10 | 低电压复合材料模具 |
Country Status (6)
Country | Link |
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US (1) | US6930579B2 (zh) |
EP (1) | EP1631972A4 (zh) |
CN (1) | CN100524550C (zh) |
BR (1) | BRPI0411251A (zh) |
CA (1) | CA2527768C (zh) |
WO (1) | WO2004114332A2 (zh) |
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CN1741210B (zh) * | 2005-09-05 | 2010-05-26 | 韶关市韶特电气有限公司 | 干式电力变压器浇注式环氧树脂线圈免切割技术 |
US7752735B2 (en) * | 2007-08-09 | 2010-07-13 | Abb Technology Ag | Coil bus transformer and a method of manufacturing the same |
WO2011029488A1 (en) * | 2009-09-11 | 2011-03-17 | Abb Research Ltd | Transformer comprising a heat pipe |
KR101820644B1 (ko) | 2010-04-07 | 2018-01-22 | 에이비비 슈바이쯔 아게 | 실외 건식 변압기 |
US9111677B2 (en) * | 2010-04-07 | 2015-08-18 | Abb Technology Ag | Method of manufacturing a dry-type open wound transformer having disc windings |
PL2528075T3 (pl) * | 2011-05-25 | 2014-04-30 | Abb Schweiz Ag | Urządzenie nawijające, sposób nawijania i uzwojenie transformatora |
CN102267210B (zh) * | 2011-08-01 | 2013-06-12 | 保定天威集团有限公司 | 一种浇注变压器线圈方法 |
US9257229B2 (en) | 2011-09-13 | 2016-02-09 | Abb Technology Ag | Cast split low voltage coil with integrated cooling duct placement after winding process |
WO2013063242A1 (en) | 2011-10-28 | 2013-05-02 | Abb Technology Ag | Integral mold for a transformer having a non-linear core |
CN103177868A (zh) * | 2013-04-09 | 2013-06-26 | 国家电网公司 | 撑模式变压器线圈组合套装台 |
US11242991B2 (en) * | 2019-05-15 | 2022-02-08 | Raytheon Technologies Corporation | CMC component arrangement and method of manufacture |
CN112117125B (zh) * | 2020-08-27 | 2022-04-08 | 江门市蓬江区恒驰新材料有限公司 | 一种自动化线圈缠胶带设备 |
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JPS5463222A (en) * | 1977-10-28 | 1979-05-22 | Mitsubishi Electric Corp | Manufacture of mold coil |
JPS5763816A (en) * | 1980-10-06 | 1982-04-17 | Hitachi Ltd | Molded transformer coil |
US4337219A (en) * | 1980-12-09 | 1982-06-29 | Square D Company | Method of encapsulating electrical coils |
JPS57121207A (en) * | 1981-01-21 | 1982-07-28 | Hitachi Ltd | Manufacture of plastic molded coil |
JPS57141902A (en) * | 1981-02-25 | 1982-09-02 | Mitsubishi Electric Corp | Insulating coil |
DE3234098A1 (de) * | 1982-09-14 | 1984-03-15 | Transformatoren Union Ag, 7000 Stuttgart | Verfahren zur herstellung in giessharz eingebetteter wicklungen fuer transformatoren |
JPS6132411A (ja) * | 1984-07-23 | 1986-02-15 | Rishiyou Kogyo Kk | 乾式トランス用モールドコイルの製造方法 |
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US6221297B1 (en) * | 1999-09-27 | 2001-04-24 | Abb Power T&D Company Inc. | Method of manufacturing a transformer coil with a disposable wrap and band mold and integrated winding mandrel |
US20020101315A1 (en) * | 2001-01-31 | 2002-08-01 | Colin Hamer | Ignition coil with primary winding release |
US6624734B2 (en) * | 2001-09-21 | 2003-09-23 | Abb Technology Ag | DC voltage/current heating/gelling/curing of resin encapsulated distribution transformer coils |
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2003
- 2003-06-11 US US10/459,055 patent/US6930579B2/en not_active Expired - Lifetime
-
2004
- 2004-06-10 EP EP04754901A patent/EP1631972A4/en not_active Withdrawn
- 2004-06-10 CN CNB2004800162000A patent/CN100524550C/zh not_active Expired - Fee Related
- 2004-06-10 CA CA2527768A patent/CA2527768C/en not_active Expired - Fee Related
- 2004-06-10 BR BRPI0411251-2A patent/BRPI0411251A/pt not_active IP Right Cessation
- 2004-06-10 WO PCT/US2004/018443 patent/WO2004114332A2/en active Search and Examination
Also Published As
Publication number | Publication date |
---|---|
US6930579B2 (en) | 2005-08-16 |
CN1806303A (zh) | 2006-07-19 |
WO2004114332A2 (en) | 2004-12-29 |
EP1631972A2 (en) | 2006-03-08 |
WO2004114332A3 (en) | 2005-10-20 |
CA2527768C (en) | 2013-10-29 |
EP1631972A4 (en) | 2011-04-06 |
US20040251998A1 (en) | 2004-12-16 |
CA2527768A1 (en) | 2004-12-29 |
BRPI0411251A (pt) | 2006-07-25 |
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