Patent Publication Number: US-2023162909-A1

Title: Waterproof transformer coil structure and manufacturing method thereof

Description:
TECHNICAL FIELD 
     The disclosure relates to the field of transformers, and more particularly, to a waterproof transformer coil structure and a manufacturing method thereof. 
     BACKGROUND 
     In recent years, underground distribution devices may be flooded and burned down due to waterlogging, which leads to interruption of power supply. Once the transformer, as the key component of a distribution device, is burned down, on-site replacement of the transformer is difficult and takes a long time, which will cause long-term power outage, seriously reduce an efficiency of power supply restoration of an urban power grid and cause great inconvenience to people&#39;s life and production. Considering aspects such as safety, reliability and fireproofing, dry-type transformer is generally used an underground transformer. Performance of the coil, as a core member of the transformer, directly affects whether the product can be operated normally. However, when the dry-type transformer undergoes waterlogging, the coil, after soaked during waterlogging, will be damp and has a reduced electrical performance or even be burnt-down, thus affecting normal operation of the product. For a traditional waterproof transformer, the coil is casted into a whole by using epoxy casting, which is complicated in process, and has high material and production costs. When the product is operated for a period of time, the coil is prone to a “crazing” phenomenon, which reduces an electrical performance and a waterproof capability of the product. 
     SUMMARY 
     The disclosure aims to solve at least one of the technical problems in the existing technology. To this end, the disclosure provides a waterproof transformer coil structure and a manufacturing method thereof. The waterproof transformer coil structure solves problems that a coil is easy to get damp and an electrical performance is lowered after a dry-type transformer is waterlogged, and the manufacturing method is provided, so that technical effects of a simple and reliable operation and improvement of a cost performance of products are achieved. 
     The disclosure provides a waterproof transformer coil structure with the functions above. The waterproof transformer coil structure includes: an insulating cylinder configured for supporting a transformer coil; a strut configured for being wound with the transformer coil, where the strut is mounted on the insulating cylinder, and the strut is provided with a plurality of strip-shaped notches; and a winding wire, where the winding wire is wound on the strip-shaped notches. 
     The waterproof transformer coil structure according to the embodiments of the disclosure at least has the following technical effects: the waterproof transformer coil structure improves waterproof and water drainage capabilities of the coil and enhances a waterproof performance of the transformer through the strut and the strip-shaped notches arranged in the strut. 
     For the waterproof transformer coil structure according to the embodiments of the disclosure, the strut is provided in plural, and the struts are evenly arranged on an outer wall of the insulating cylinder, so that the struts are evenly distributed on the insulating cylinder. The struts can enhance a water drainage capability of the waterproof transformer coil, water can flow out of the coil along the struts without water accumulation, and the even distribution of the struts on the insulating cylinder can enhance a mechanical strength of the insulating cylinder. 
     For the waterproof transformer coil structure according to the embodiments of the disclosure, the strip-shaped notches are evenly arranged on an outer edge of the strut, so that the strip-shaped notches are evenly disputed on the strut. The even distribution of the strip-shaped notches on the strut can enhance a mechanical strength of the strut, and the winding wire is wound on the strip-shaped notches, so that the even distribution of the strip-shaped notches can maintain an electrical performance of the transformer. 
     For the waterproof transformer coil structure according to the embodiments of the disclosure, two ends of the strut are respectively provided with a bending notch which is convenient for water drainage. An angle ring is inserted into the bending notch, which can enhance an electrical performance and reduce accumulated water in the coil. 
     For the waterproof transformer coil structure according to the embodiments of the disclosure, the bending notch includes an inclined portion convenient for water drainage and a vertical portion, and the inclined portion is connected with the vertical portion. The inclined portion is convenient for water drainage, and after the angle ring is inserted into the vertical portion, the electrical performance can be enhanced and the accumulated water in the coil can be reduced. 
     The waterproof transformer coil structure according to the embodiments of the disclosure further includes an angle ring, where an outer end face of the angle ring is lower than an inner end face of the angle ring, the angle ring is arranged on the bending notch of the strut, and the angle ring is made of silicone rubber material. Arrangement of the outer end face of the angle ring being lower than the inner end face of the angle ring can facilitate outflow of the water, and reduce a probability of water accumulation in the transformer coil. 
     For the waterproof transformer coil structure according to the embodiments of the disclosure, the winding wire includes a metal wire conductor, a first polyimide film, a first insulating paper, a second insulating paper and a second polyimide film. The metal wire conductor, the first polyimide film, the first insulating paper, the second insulating paper and the second polyimide film are wrapped in sequence, and the winding wire is wound on the strip-shaped notches. Wrapping of the metal wire conductor, the first polyimide film, the first insulating paper, the second insulating paper and the second polyimide film in sequence can enhance insulation of the metal wire conductor, and prevent short circuit caused by water soaking. 
     The waterproof transformer coil structure according to the embodiments of the disclosure further includes an insulating ring arranged on both end faces of the winding wire, and the insulating ring is made of an insulating material. The insulating rings are used for enhancing an insulating performance of the transformer coil. 
     A method for manufacturing the waterproof transformer coil according to the embodiments of the disclosure includes: machining an insulating material or an insulating plate into a cylindrical structure to form an insulating cylinder; machining an insulating material into a plurality of struts, and machining a plurality of strip-shaped notches in a middle portion of each of the struts; evenly distributing and fixing the struts on a surface of the insulating cylinder; and winding a winding wire on the strip-shaped notches of the strut to form a pie winding. 
     The method for manufacturing the waterproof transformer coil according to the embodiments of the disclosure further: inserting an insulating ring on both upper and lower end faces of the pie winding; inserting an angle ring along a bending notch of the strut; performing primary roasting on the waterproof transformer coil; performing primary vacuum immersion paint on the waterproof transformer coil; performing secondary roasting on the waterproof transformer coil; performing secondary vacuum immersion paint on the waterproof transformer coil; performing third roasting on the waterproof transformer coil; and coating hydrophobic paint on a surface of the waterproof transformer coil. 
     The additional aspects and advantages of the disclosure will be given in part in the following description, and will become apparent in part from the following description, or will be learned through the practice of the disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and/or additional aspects and advantages of the disclosure will be apparent and easily understood from the description of the embodiments with reference to the following accompanying drawings, wherein: 
         FIG.  1    is a schematic diagram of a waterproof transformer coil structure according to the embodiments of the disclosure; 
         FIG.  2    is a schematic diagram of a strut of the waterproof transformer coil structure according to the embodiments of the disclosure; 
         FIG.  3    is a schematic diagram of a winding wire of the waterproof transformer coil structure according to the embodiments of the disclosure; 
         FIG.  4    is a schematic diagram of an angle ring of the waterproof transformer coil structure according to the embodiments of the disclosure; and 
         FIG.  5    is a schematic diagram of an insulating ring of the waterproof transformer coil structure according to the embodiments of the disclosure. 
     
    
    
     Reference numerals: 
       101  refers to insulating cylinder, 
       201  refers to strut,  202  refers to strip-shaped notch,  230  refers to bending notch,  204  refers to inclined portion,  205  refers to vertical portion, 
       301  refers to winding wire,  302  refers to metal wire conductor,  303  refers to first polyimide film,  304  refers to first insulating paper,  305  refers to second insulating paper,  306  refers to second polyimide film, 
       401  refers to angle ring, and 
       501  refers to insulating ring. 
     DETAILED DESCRIPTION 
     The embodiments of the disclosure are described below in detail. Examples of the embodiments are shown in the accompanying drawings. The same or similar numerals represent the same or similar elements or elements having the same or similar functions throughout the specification. The embodiments described below with reference to the accompanying drawings are exemplary, and are only used to explain the disclosure but should not be construed as a limitation to the disclosure. 
     In the description of the disclosure, it should be understood that the positional descriptions referred to, for example, the directional or positional relationships indicated by up, down, front, rear, left, right, etc., are based on the directional or positional relationships shown in the drawings, and are only for convenience and simplification of description of the disclosure, but not for indicating or implying that the referred device or element must have a specific direction, be constructed and operated in a specific direction, and thus should not be construed as limiting the disclosure. 
     In the description of the disclosure, “several” means one or more, “a plurality of” means more than two, “greater than a number”, “less than a number”, “exceed a number” and the like indicate that the number is excluded, and “above a number”, “below a number”, “within a number”, and the like indicate that the number is included. “First” and “second” are only used to distinguish between technical features but cannot be used to indicate or imply relative importance or implicitly specify a quantity of indicated technical features or implicitly specify a sequential relationship of indicated technical features. 
     In the description of the disclosure, unless otherwise expressly defined, the terms such as “disposed”, “mounted”, and “connected” should be understood in a broad sense. For persons of ordinary skill in the art, specific meanings of the terms in the disclosure may be appropriately determined with reference to the specific content in the technical solution. 
     With reference to  FIG.  1   , the disclosure provides a waterproof transformer coil structure with the functions described above. The waterproof transformer coil structure includes: an insulating cylinder  101  configured for supporting a transformer coil; a strut  201  configured for being wound with the transformer coil, where the strut  201  is mounted on the insulating cylinder  101 , and the strut  201  is provided with strip-shaped notches  202 ; and a winding wire  301 , where the winding wire  301  is wound on the strip-shaped notches  202 . 
     With reference to  FIG.  1   , the waterproof transformer coil structure according to the embodiments of the disclosure at least has the following technical effects: the waterproof transformer coil structure improves waterproof and water drainage capabilities of the coil and enhances a waterproof performance of the transformer through the strut  201  and the strip-shaped notches  202  arranged in the strut  201 . 
     With reference to  FIG.  2   , for the waterproof transformer coil structure according to the embodiments of the disclosure, a plurality of struts  201  are provided, and the struts  201  are evenly arranged on an outer wall of the insulating cylinder  101 , so that the struts  201  are evenly distributed on the insulating cylinder  101 . The struts  201  can enhance a water drainage capability of the waterproof transformer coil, water can flow out of the coil along the struts  201  without water accumulation, and even distribution of the struts  201  on the insulating cylinder  101  can enhance a mechanical strength of the insulating cylinder  101 . 
     With reference to  FIG.  2   , for the waterproof transformer coil structure according to the embodiments of the disclosure, the strip-shaped notches  202  are evenly arranged on an outer edge of the strut  201 , so that the strip-shaped notches  202  are evenly disputed on the strut  201 . The even distribution of the strip-shaped notches  202  on the strut  201  can enhance a mechanical strength of the strut  201 , and the winding wire  301  is wound on the strip-shaped notches  202 , so that the even distribution of the strip-shaped notches  202  can maintain an electrical performance of the transformer. 
     With reference to  FIG.  2   , for the waterproof transformer coil structure according to the embodiments of the disclosure, two ends of the strut  201  are respectively provided with a bending notch  203  which is convenient for water drainage. An angle ring  401  is inserted into the bending notch  203 , which can enhance an electrical performance and reduce accumulated water in the coil. 
     With reference to  FIG.  2   , for the waterproof transformer coil structure according to the embodiments of the disclosure, the bending notch  203  includes an inclined portion  204  convenient for water drainage and a vertical portion  205 , and the inclined portion  204  is connected with the vertical portion  205 . The inclined portion  204  is convenient for water drainage, and after the angle ring  401  inserted into the vertical portion  205 , the electrical performance can be enhanced and the accumulated water in the coil can be reduced. 
     With reference to  FIG.  1    and  FIG.  4   , the waterproof transformer coil structure according to the embodiments of the disclosure further includes an angle ring  401 , where an outer end face of the angle ring  401  is lower than an inner end face of the angle ring  401 , the angle ring  401  is arranged in the bending notch  203  of the strut  201 , and the angle ring  401  is made of a silicone rubber material. Arrangement of the outer end face of the angle ring  401  being lower than the inner end face of the angle ring  401  can facilitate outflow of the water, and reduce a probability of water accumulation in the transformer coil. 
     With reference to  FIG.  1    and  FIG.  3   , for the waterproof transformer coil structure according to the embodiments of the disclosure, the winding wire  301  includes a metal wire conductor  302 , a first polyimide film  303 , a first insulating paper  304 , a second insulating paper  305  and a second polyimide film  306 . The metal wire conductor  302 , the first polyimide film  303 , the first insulating paper  304 , the second insulating paper  305  and the second polyimide film  306  are wrapped in sequence, and the winding wire  301  is wound on the strip-shaped notches  202 . Wrapping of the metal wire conductor  302 , the first polyimide film  303 , the first insulating paper  304 , the second insulating paper  305  and the second polyimide film  306  in sequence can enhance insulation of the metal wire conductor  302 , and prevent short circuit caused by water soaking. 
     With reference to  FIG.  1    and  FIG.  5   , the waterproof transformer coil structure according to the embodiments of the disclosure further includes an insulating ring  501  on both end faces of the winding wire  301 , and the insulating ring  501  is made of insulating material. The insulating ring  501  is used for enhancing an insulating performance of the transformer coil. 
     With reference to  FIG.  1   , a method for manufacturing the waterproof transformer coil according to the embodiments of the disclosure includes the following steps of: machining an insulating material or an insulating plate into a cylindrical structure to form an insulating cylinder  101 ; machining an insulating material into struts  201 , and machining strip-shaped notches  202  in a middle portion of each of the struts  201 ; evenly distributing and fixing the struts  201  on a surface of the insulating cylinder  101 ; and winding the winding wire  301  on the strip-shaped notches  202  of the struts  201  to form a pie winding. 
     With reference to  FIG.  1   , the method for manufacturing the waterproof transformer coil according to the embodiments of the disclosure further includes the steps of: inserting an insulating ring  501  on both upper and lower end faces of the pie winding; inserting an angle ring  401  along a bending notch  203  of each of the struts  201 ; performing primary roasting on the waterproof transformer coil; performing primary vacuum immersion paint on the waterproof transformer coil; performing secondary roasting on the waterproof transformer coil; performing secondary vacuum immersion paint on the waterproof transformer coil; performing third roasting on the waterproof transformer coil; and coating hydrophobic paint on a surface of the waterproof transformer coil. 
     The embodiments of the disclosure are described in detail with reference to the accompanying drawings above, but the disclosure is not limited to the above embodiments, and various changes may also be made within the knowledge scope of those of ordinary skills in the art without departing from the purpose of the disclosure. 
     In the description of the disclosure, the descriptions referring to the terms “one embodiment”, “some embodiments”, “schematic embodiments”, “examples”, “specific examples”, or “some examples” mean that the specific features, structures, materials, or characteristics described in combination with the embodiment or example are included in at least one embodiment or example of the disclosure. In the specification, the schematic representation of the above terms does not necessarily mean the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. 
     Although the embodiments of the disclosure have been shown and described, those of ordinary skills in the art may understand that various changes, modifications, substitutions and variations may be made to these embodiments without departing from the principle and purpose of the disclosure, and the scope of the disclosure is defined by the claims and their equivalents.