A high-power, high-efficiency, heat-dissipating, low-leakage magnetic foil-wound high-frequency transformer

Abstract

The invention discloses a high-power, high-efficiency, heat-dissipating, low-magnetic leakage foil-wound high-frequency transformer, comprising a magnetic core and a foil-wound coil; the magnetic core has two winding magnetic columns and an upper side portion and a lower side portion; the magnetic core is mounted on an aluminum plate radiator; two groups of foil-wound coils are arranged, and each group of foil-wound coils is arranged around a winding magnetic column; the foil-wound coil has an inner secondary foil-wound coil, a primary foil-wound coil, and an outer secondary foil-wound coil arranged in sequence from the inside to the outside, and the inner secondary foil-wound coil and the outer secondary foil-wound coil are connected and conducted through a first conductor; or the foil-wound coil has an inner primary foil-wound coil, a secondary foil-wound coil, and an outer primary foil-wound coil arranged in sequence from the inside to the outside, and the inner primary foil-wound coil and the outer primary foil-wound coil are connected and conducted through a second conductor. In this way, the purposes of improving coupling, reducing magnetic leakage, improving conversion efficiency, reducing product size, and improving heat dissipation efficiency are achieved, and at the same time, its structure is ingenious and reasonable, and can be mass-produced.

Description

Technical Field

[0001] The invention relates to the field of high-power high-frequency transformer technology, and in particular to a high-power, high-efficiency, heat-dissipating and low-leakage magnetic foil-wound high-frequency transformer. Background Art

[0002] In traditional technology, high-frequency transformers usually use a secondary coil wrapped around the primary coil. Due to the serious skin effect of high-frequency current, the current will preferentially flow along the shortest inner path, resulting in loose magnetic coupling between the primary and secondary. Therefore, the transformer has the defects of large leakage flux and low efficiency. In order to minimize the leakage flux, the coil is usually wound very tightly, which brings about the problem of poor heat dissipation, because the heat inside the tightly wound coil is difficult to conduct away. Some methods also reduce the number of coil turns by lengthening the core height, but the core usage is large, the weight is large, the cost is high, and the height dimension of the entire high-frequency transformer is large.

[0003] Therefore, in the present invention, the applicant has carefully studied a new technical solution to solve the above problems. Summary of the invention

[0004] In view of this, the present invention aims to address the deficiencies in the prior art, and its main purpose is to provide a high-power, high-efficiency, heat-dissipating, low-leakage magnetic foil-wound high-frequency transformer, which can achieve the purposes of enhancing coupling, reducing leakage magnetic field, improving conversion efficiency, reducing product size, and improving heat dissipation efficiency. At the same time, its structure is ingenious and reasonable, and can be mass-produced.

[0005] To achieve the above purpose, the present invention adopts the following technical solutions:

[0006] A high-power, high-efficiency, heat-dissipating, low-leakage magnetic foil-wound high-frequency transformer, comprising a magnetic core and a foil-wound coil; wherein:

[0007] The magnetic core has two winding magnetic columns arranged at a left-right interval and an upper side portion and a lower side portion respectively connected to the upper ends and lower ends of the two winding magnetic columns; the magnetic core is mounted on an aluminum plate radiator;

[0008] The foil-wound coils are provided in two groups, and each group of foil-wound coils is provided around a winding magnetic column;

[0009] The foil-wound coil comprises an inner secondary foil-wound coil, a primary foil-wound coil and an outer secondary foil-wound coil which are sequentially arranged from the inside to the outside, and the inner secondary foil-wound coil and the outer secondary foil-wound coil are connected and conducted via a first conductor; or, the foil-wound coil comprises an inner primary foil-wound coil, a secondary foil-wound coil and an outer primary foil-wound coil which are sequentially arranged from the inside to the outside, and the inner primary foil-wound coil and the outer primary foil-wound coil are connected and conducted via a second conductor.

[0010] As a preferred embodiment, the number of turns of the inner secondary foil-wound coil, the primary foil-wound coil and the outer secondary foil-wound coil are all more than 1 turn, and the number of turns of the outer secondary foil-wound coil is equal to the number of turns of the primary foil-wound coil minus the number of turns of the inner secondary foil-wound coil.

[0011] As a preferred embodiment, the number of turns of the inner primary foil winding coil, the secondary foil winding coil and the outer primary foil winding coil are all more than 1 turn, and the number of turns of the outer primary foil winding coil is equal to the number of turns of the secondary foil winding coil minus the number of turns of the inner primary foil winding coil.

[0012] As a preferred solution, a first insulating layer is provided between adjacent inner secondary foil-wound coils, primary foil-wound coils and outer secondary foil-wound coils.

[0013] As a preferred solution, a second insulating layer is provided between adjacent inner primary foil-wound coils, secondary foil-wound coils and outer primary foil-wound coils.

[0014] As a preferred solution, the magnetic core is stacked in a front-to-back direction, and the aluminum plate radiator has an internal heat sink and an external heat sink. The internal heat sink is sandwiched between adjacent magnetic cores, and the internal heat sink absorbs the heat of the magnetic core and conducts it to the external heat sink; and the external heat sink is arranged in a wrapping manner along the magnetic core.

[0015] As a preferred solution, the internal heat dissipation plates are extended left and right, and the external heat dissipation plates are connected to the left and right ends of the corresponding internal heat dissipation plates.

[0016] As a preferred solution, each internal heat sink and the external heat sinks connected to the left and right ends thereof constitute an aluminum plate heat sink unit, and the aluminum plate radiator includes a plurality of aluminum plate heat sink units.

[0017] As a preferred embodiment, a conductive foil is provided at the upper end or the lower end of each group of foil-wound coils, and the joints of the inner secondary foil-wound coil and the outer secondary foil-wound coil extend to the conductive foil to be conductive, or the joints of the inner primary foil-wound coil and the outer primary foil-wound coil extend to the conductive foil to be conductive.

[0018] As a preferred solution, the magnetic core and the aluminum plate heat sink are connected and fixed by thermally conductive adhesive.

[0019] Compared with the prior art, the present invention has obvious advantages and beneficial effects. Specifically, it can be seen from the above technical scheme that it achieves the purposes of improving coupling, reducing magnetic leakage, improving conversion efficiency, reducing product size, and improving heat dissipation capacity. At the same time, its structure is ingenious and reasonable, and can be mass-produced.

[0020] Secondly, by designing the foil-wound coil as an inner secondary foil-wound coil, a primary foil-wound coil and an outer secondary foil-wound coil, or an inner primary foil-wound coil, a secondary foil-wound coil and an outer primary foil-wound coil, the coupling between the primary and secondary is effectively improved, and magnetic leakage is reduced. The foil-wound design also makes it possible to control the product volume to be relatively small while meeting the high power requirement.

[0021] Furthermore, the upper or lower end of each group of foil-wound coils is provided with conductive foil to achieve joint conduction, which is beneficial to control the overall thickness of the foil-wound coils and is also suitable for automated electrical connection;

[0022] Furthermore, by designing the magnetic cores as the first magnetic core, the second magnetic core, the third magnetic core, and the fourth magnetic core; and designing the aluminum plate heat sink as the first aluminum plate, the second aluminum plate, and the third aluminum plate arranged in sequence front to back; in this way, the internal heat of the transformer is effectively conducted outward, and the heat dissipation efficiency is high; at the same time, for magnetic cores of different heights, this kind of magnetic core and aluminum plate heat sink structure can achieve modular stacking combination by adding a second aluminum plate to obtain magnetic cores of corresponding heights. In the factory production link, the process has good versatility, which is conducive to improving production efficiency.

[0023] In order to more clearly illustrate the structural features and effects of the present invention, the present invention is described in detail below in conjunction with the accompanying drawings and specific embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a front view of an embodiment of the present invention;

[0025] Figure 2 is a side view of an embodiment of the present invention;

[0026] Figure 3 is a front view of a magnetic core according to an embodiment of the present invention;

[0027] Figure 4 is a side view of a magnetic core according to an embodiment of the present invention;

[0028] Figure 5 is a front view of a foil-wound coil according to an embodiment of the present invention;

[0029] Figure 6 is a side view of a foil-wound coil according to an embodiment of the present invention;

[0030] Figure 7 is a top view of a foil-wound coil according to an embodiment of the present invention;

[0031] Figure 8 It is an exploded view of an aluminum plate radiator according to an embodiment of the present invention.

[0032] Description of the accompanying drawings:

[0033] 10. Magnetic core 101. First magnetic core

[0034] 102, second magnetic core 103, third magnetic core

[0035] 104, fourth magnetic core 11, winding magnetic column

[0036] 12. Upper side 13. Lower side

[0037] 20. Foil-wound coil 211. Inner secondary foil-wound coil

[0038] 212, primary foil coil 213, outer secondary foil coil

[0039] 214. First insulation layer

[0040] 30. Aluminum plate radiator 31. First aluminum plate

[0041] 32. Second aluminum plate 33. Third aluminum plate DETAILED DESCRIPTION

[0042] Please refer to Figures 1 to 8 As shown, it shows the specific structure of an embodiment of the present invention.

[0043] A high-power, high-efficiency, heat-dissipating, low-leakage magnetic foil-wound high-frequency transformer comprises a magnetic core 10 and a foil-wound coil 20; wherein:

[0044] The magnetic core 10 has two winding magnetic columns 11 arranged at a left-right interval and an upper side portion 12 and a lower side portion 13 respectively connected to the upper ends and lower ends of the two winding magnetic columns 11; the magnetic core 10 is mounted on an aluminum plate heat sink 30;

[0045] The foil-wound coils 20 are provided in two groups, and each group of foil-wound coils 20 is provided around a winding magnetic column 11;

[0046] The foil coil 20 has an inner secondary foil coil 211, a primary foil coil 212 and an outer secondary foil coil 213 arranged in sequence from the inside to the outside, and the inner secondary foil coil 211 and the outer secondary foil coil 213 are connected and conducted through a first conductor; usually, the number of turns of the inner secondary foil coil 211, the primary foil coil 212 and the outer secondary foil coil 213 is more than one turn, and the number of turns of the outer secondary foil coil 213 is equal to the number of turns of the primary foil coil 212 minus the number of turns of the inner secondary foil coil 211. A first insulating layer 214 is arranged between the inner secondary foil coil 211, the primary foil coil 212 and the outer secondary foil coil 213.

[0047] Alternatively, the foil-wound coil has an inner primary foil-wound coil, a secondary foil-wound coil, and an outer primary foil-wound coil arranged in sequence from the inside to the outside, and the inner primary foil-wound coil and the outer primary foil-wound coil are connected and conducted through a second conductor. Usually, the number of turns of the inner primary foil-wound coil, the secondary foil-wound coil, and the outer primary foil-wound coil is more than 1 turn, and the number of turns of the outer primary foil-wound coil is equal to the number of turns of the secondary foil-wound coil minus the number of turns of the inner primary foil-wound coil. A second insulating layer is arranged between the inner primary foil-wound coil, the secondary foil-wound coil, and the outer primary foil-wound coil.

[0048] Preferably, a conductive foil is provided at the upper end or the lower end of each group of foil-wound coils 20, and the joints of the inner secondary foil-wound coil and the outer secondary foil-wound coil extend to the conductive foil for conduction, or the joints of the inner primary foil-wound coil and the outer primary foil-wound coil extend to the conductive foil for conduction. Conductive foil is used to achieve joint conduction, which is conducive to controlling the entire thickness of the foil-wound coil and is also suitable for automated electrical connection.

[0049] The magnetic core is stacked with several ones in the front-to-back direction, and the aluminum plate radiator has an internal radiator and an external radiator. The internal radiator is sandwiched between adjacent magnetic cores, and the internal radiator absorbs the heat of the magnetic core and conducts it to the external radiator; and the external radiator is arranged along the magnetic core in a wrapped manner. Here, the internal radiator is extended left and right, and the external radiator is connected to the left and right ends of the corresponding internal radiator. Each internal radiator and the external radiator connected to its left and right ends constitute an aluminum plate radiator unit, and the aluminum plate radiator includes several aluminum plate radiator units. During assembly, the magnetic core and the aluminum plate radiator are connected and fixed by thermal conductive glue.

[0050] In this embodiment, a specific structure of a magnetic core 10 and a corresponding aluminum plate heat sink 30 is provided. Figure 4 and Figure 8 The magnetic core 10 includes a first magnetic core 101, a second magnetic core 102, a third magnetic core 103, and a fourth magnetic core 104, all of which are designed in a mouth shape; the magnetic core 10 adopts a ferrite core, which increases the magnetic permeability and is also conducive to controlling the cost of the magnetic core.

[0051] The aluminum plate radiator 30 includes a first aluminum plate 31, a second aluminum plate 32 and a third aluminum plate 33 arranged in sequence; wherein:

[0052] The first aluminum plate 31 includes a first substrate and a first top plate and a first bottom plate extending forward from the upper and lower ends of the first substrate, respectively. The first substrate is provided with a first through hole, so that the first substrate has a first plate frame surrounding the first through hole. The first plate frame and the first top plate and the first bottom plate form a first area for accommodating the first magnetic core 101.

[0053] The second aluminum plate 32 includes a second substrate and a second top plate and a second bottom plate extending forward and backward from the upper and lower ends of the second substrate, respectively. The second substrate is provided with a second through hole, so that the second substrate has a second plate frame surrounding the second through hole. The second plate frame and the second top plate and the second bottom plate are constructed to form a second area for accommodating the second magnetic core 102 and a third area for accommodating the third magnetic core 103. The second area and the third area are respectively located at the front and rear sides of the second substrate.

[0054] The third aluminum plate 33 includes a third substrate and a third top plate and a third bottom plate extending backward from the corresponding upper and lower ends of the third substrate. The third substrate is provided with a third through hole so that the third substrate has a third plate frame surrounding the third through hole. The third plate frame and the third top plate and the third bottom plate form a fourth area for accommodating the fourth magnetic core 104.

[0055] like Figure 8 As shown, the first aluminum plate 31, the second aluminum plate 32 and the third aluminum plate 33 can be designed as an integrated structure, that is, the first aluminum plate 31 and the third aluminum plate 33 are both integrated U-shaped structures, and the second aluminum plate 32 is an integrated I-shaped structure; preferably, the first aluminum plate 31, the second aluminum plate 32 and the third aluminum plate 33 can be designed as an integrated structure, all of which are assembled from upper and lower parts, usually in half at the first substrate, the second substrate, and the third substrate, which are easy to produce and assemble.

[0056] In actual production, the first aluminum plate 31, the second aluminum plate 32 and the third aluminum plate 33 are connected and fixed to the corresponding first magnetic core 101, the second magnetic core 102, the third magnetic core 103 and the fourth magnetic core 104 by thermal conductive glue. The gaps between the first aluminum plate 31, the second aluminum plate 32 and the third aluminum plate 33 and the corresponding first magnetic core 101, the second magnetic core 102, the third magnetic core 103 and the fourth magnetic core 104 are filled with glue to fill the gaps. Preferably, 1060 aluminum is used to make the first aluminum plate 31, the second aluminum plate 32 and the third aluminum plate 33. Actual tests have shown that by adopting this heat dissipation structure, the measured temperature of the entire high-frequency transformer can be reduced by 20-30 degrees Celsius.

[0057] It should be noted that, in actual design and production, the specific design forms of the aforementioned magnetic core 10 and the corresponding aluminum plate heat sink 30 are not limited. The number of magnetic cores 10 and the corresponding aluminum plate heat sink 30, the specific detailed structure, etc. can be flexibly changed. Usually, as the power demand increases, the number of magnetic cores 10 and the corresponding aluminum plate heat sink 30 also increases accordingly.

[0058] The design focus of the present invention is to achieve the purposes of improving coupling, reducing magnetic leakage, improving conversion efficiency, reducing product size, and improving heat dissipation capacity. At the same time, its structure is ingenious and reasonable, and can be mass-produced.

[0059] Secondly, by designing the foil-wound coil into an inner secondary foil-wound coil, a primary foil-wound coil and an outer secondary foil-wound coil, or an inner primary foil-wound coil, a secondary foil-wound coil and an outer primary foil-wound coil, the coupling between the primary and secondary is effectively improved and magnetic leakage is reduced. The foil-wound design also allows the product volume to be controlled to be smaller while meeting high power requirements.

[0060] Furthermore, the upper or lower end of each group of foil-wound coils is provided with conductive foil to achieve joint conduction, which is beneficial to control the overall thickness of the foil-wound coils and is also suitable for automated electrical connection.

[0061] Furthermore, by designing the magnetic cores as the first magnetic core, the second magnetic core, the third magnetic core, and the fourth magnetic core; and designing the aluminum plate heat sink as the first aluminum plate, the second aluminum plate, and the third aluminum plate arranged in sequence front to back; in this way, the internal heat of the transformer is effectively conducted outward, and the heat dissipation efficiency is high; at the same time, for magnetic cores of different heights, this kind of magnetic core and aluminum plate heat sink structure can achieve modular stacking combination by adding a second aluminum plate to obtain magnetic cores of corresponding heights. In the factory production link, the process has good versatility, which is conducive to improving production efficiency.

Claims

1. A high-power, high-efficiency, heat-dissipating, low-leakage magnetic foil-wound high-frequency transformer, characterized in that: It includes a magnetic core and a foil-wound coil; wherein: The magnetic core comprises two winding magnetic columns arranged at a left-right interval and an upper side portion and a lower side portion respectively connected to the upper ends and lower ends of the two winding magnetic columns; The foil-wound coils are provided in two groups, and each group of foil-wound coils is provided around a winding magnetic column; The foil-wound coil comprises an inner secondary foil-wound coil, a primary foil-wound coil and an outer secondary foil-wound coil which are sequentially arranged from the inside to the outside, and the inner secondary foil-wound coil and the outer secondary foil-wound coil are connected and conducted via a first conductor; or, the foil-wound coil comprises an inner primary foil-wound coil, a secondary foil-wound coil and an outer primary foil-wound coil which are sequentially arranged from the inside to the outside, and the inner primary foil-wound coil and the outer primary foil-wound coil are connected and conducted via a second conductor; a conductive foil is arranged at the upper end or the lower end of each group of foil-wound coils, and the joints of the inner secondary foil-wound coil and the outer secondary foil-wound coil extend to the conductive foil to be conducted, or, the joints of the inner primary foil-wound coil and the outer primary foil-wound coil extend to the conductive foil to be conducted; The magnetic core is installed on an aluminum plate radiator; the aluminum plate radiator includes a first aluminum plate, a second aluminum plate and a third aluminum plate arranged in sequence front to back, and the first aluminum plate, the second aluminum plate and the third aluminum plate are all made of 1060 aluminum material; wherein: the first aluminum plate includes a first substrate and a first top plate and a first bottom plate extending forward from the corresponding upper and lower ends of the first substrate, and a first through hole is provided on the first substrate so that the first substrate has a first plate frame surrounding the first through hole, and the first plate frame and the first top plate and the first bottom plate are formed to form a first area for accommodating the first magnetic core; the second aluminum plate includes a second substrate and a second top plate and a second bottom plate extending forward and backward from the corresponding upper and lower ends of the second substrate, and a second through hole is provided on the second substrate so that the second substrate has a second plate frame surrounding the second through hole, and the second plate The frame and the second top plate and the second bottom plate are surrounded to form a second area for accommodating the second magnetic core and a third area for accommodating the third magnetic core, and the second area and the third area are respectively located at the front and rear sides of the second substrate; the third aluminum plate includes a third substrate and a third top plate and a third bottom plate extending backward from the corresponding upper and lower ends of the third substrate, and a third through hole is provided on the third substrate so that the third substrate has a third plate frame surrounding the third through hole, and the third plate frame and the third top plate and the third bottom plate are surrounded to form a fourth area for accommodating the fourth magnetic core; and the first aluminum plate and the third aluminum plate are both integrated U-shaped structures, the second aluminum plate is an integrated I-shaped structure, and the first aluminum plate, the second aluminum plate and the third aluminum plate are all assembled from upper and lower parts, and the first substrate, the second substrate and the third substrate are assembled in half; The magnetic core comprises a first magnetic core, a second magnetic core, a third magnetic core and a fourth magnetic core, all of which are designed in a mouth shape, and the magnetic core is a ferrite magnetic core; The first aluminum plate, the second aluminum plate, and the third aluminum plate are connected and fixed to the corresponding first magnetic core, the second magnetic core, the third magnetic core, and the fourth magnetic core by means of thermal conductive glue, and glue is poured into the gaps between the first aluminum plate, the second aluminum plate, and the third aluminum plate and the corresponding first magnetic core, the second magnetic core, the third magnetic core, and the fourth magnetic core to fill the gaps.

2. The high-power, high-efficiency, heat-dissipating, low-leakage magnetic foil-wound high-frequency transformer according to claim 1 is characterized in that: The number of turns of the inner secondary foil winding coil, the primary foil winding coil and the outer secondary foil winding coil are all more than one turn, and the number of turns of the outer secondary foil winding coil is equal to the number of turns of the primary foil winding coil minus the number of turns of the inner secondary foil winding coil.

3. The high-power, high-efficiency, heat-dissipating, low-leakage magnetic foil-wound high-frequency transformer according to claim 1 is characterized in that: The number of turns of the inner primary foil winding coil, the secondary foil winding coil and the outer primary foil winding coil are all more than one turn, and the number of turns of the outer primary foil winding coil is equal to the number of turns of the secondary foil winding coil minus the number of turns of the inner primary foil winding coil.

4. The high-power, high-efficiency, heat-dissipating, low-leakage magnetic foil-wound high-frequency transformer according to claim 1, characterized in that: A first insulating layer is arranged between the inner secondary foil-wound coil, the primary foil-wound coil and the outer secondary foil-wound coil.

5. The high-power, high-efficiency, heat-dissipating, low-leakage magnetic foil-wound high-frequency transformer according to claim 1, characterized in that: A second insulating layer is provided between the inner primary foil-wound coil, the secondary foil-wound coil and the outer primary foil-wound coil.

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