Flat transformer for vehicle-mounted DCAC power supply

Abstract

The invention relates to the technical field of transformers in vehicle-mounted DCAC (direct current alternating current) power supplies, in particular to a flat transformer for a vehicle-mounted DCAC power supply, which comprises a framework, a magnetic core part and a coil, the framework is composed of a base and a sleeve, the base is annular and is provided with a mounting groove, and a dispensing groove and a reinforcing assembly are arranged in the mounting groove; the magnetic core part comprises an E-shaped magnetic core seat and a magnetic core plate, the magnetic core seat can be arranged in the sleeve in a penetrating manner and is fixed on the base through dispensing, and the magnetic core plate is fixedly connected with the magnetic core seat through flexible glue; the coil comprises a starting coil, a first coil and a second coil which are separated through gaskets, and all the components are matched in height and fixedly connected through flexible glue. Flexible fixed connection between the base and the magnetic core is achieved, the soft rubber has certain elastic deformation capacity, stress caused by vibration can be absorbed in the vehicle running process, and therefore the situation that the magnetic core and the base generate relative displacement in the vehicle moving process, and consequently the magnetic core is broken is avoided.

Description

Technical Field

[0001] The present application relates to the technical field of transformers in vehicle-mounted DCAC power supplies, and in particular to a flat-plate transformer for a vehicle-mounted DCAC power supply. Background Art

[0002] As an important on-board power conversion device, the on-board DC to AC inverter is widely used in various types of fuel vehicles. It converts the direct current (DC) provided by the vehicle battery into alternating current (AC) to provide power support for various external AC electrical devices. This inverter can not only meet the use needs of electronic devices in the car, such as laptops, mobile phone chargers, etc., but also drive the car audio system and even support the operation of power tools and air conditioning systems. In addition, during camping or outdoor leisure activities, the inverter can also power household appliances such as rice cookers and electric blankets, greatly improving the user's travel experience and convenience. In order to meet higher performance requirements, such as improving efficiency, reducing size, and enhancing reliability, researchers and technicians have been exploring new design solutions and manufacturing processes.

[0003] At present, in the design of flat transformers for vehicle-mounted DCAC power supplies, common methods include using traditional E-type core structures and flat core structures. The traditional E-type core structure is widely used due to its simple geometry and mature production process, but it has large volume and weight problems. The flat core structure effectively reduces the volume and weight and improves the heat dissipation performance by optimizing the magnetic circuit design.

[0004] In the prior art, flat-plate transformers use screws or other fasteners to fix the magnetic core to the frame, or design special buckle structures to achieve quick installation. However, the connection methods using screws, fasteners or buckle structures are all rigid connection methods. Such rigid connection methods are prone to cause the magnetic core to break when the vehicle shakes frequently during driving, thereby affecting the product life and safety. Summary of the invention

[0005] In order to overcome the above technical problems, the present application provides a flat transformer for a vehicle-mounted DCAC power supply.

[0006] The present application provides a flat-plate transformer for a vehicle-mounted DCAC power supply, which adopts the following technical solution: A flat transformer for a vehicle-mounted DCAC power supply, comprising a skeleton, a magnetic core and a coil; the skeleton comprises a base and a sleeve, the sleeve is fixedly connected to the top center of the base, the base is annular and coaxially arranged with the sleeve, and the coil is sleeved on the sleeve; the magnetic core comprises a magnetic core seat and a magnetic core plate, the magnetic core seat is in a mountain shape, the center of the magnetic core seat is adapted to the size of the sleeve, the center of the magnetic core seat can be inserted into the sleeve, the bottom of the magnetic core seat can be connected to the base, and the magnetic core plate is arranged on the top of the magnetic core seat and can be connected to the magnetic core seat; A mounting groove is provided at the bottom of the base, and the size of the mounting groove is adapted to the size of the bottom of the magnetic core seat. When the magnetic core seat is installed on the frame and the center of the magnetic core seat is inserted into the sleeve, a preset distance is left between the magnetic core seat and the side wall of the mounting groove. The preset distance forms a glue dispensing groove, and soft glue can be dispensed in the glue dispensing groove. The magnetic core seat and the base can be fixedly connected by the soft glue in the glue dispensing groove. A reinforcement component is also provided in the mounting groove, and the reinforcement component is used to strengthen the overall stability of the base.

[0007] By adopting the above technical solution, the flat-plate transformer for vehicle-mounted DCAC power supply has the following effects: the design of the skeleton enables the core seat to be stably installed on the base, while ensuring good electrical performance and heat dissipation capabilities; the structural design of the core part enables precise matching between the core seat and the sleeve, thereby improving the electromagnetic conversion efficiency; the mounting groove on the base is combined with the glue dispensing groove to ensure a firm connection between the core seat and the base, thereby enhancing the stability of the overall structure; the setting of the reinforcement component further enhances the overall strength of the base, effectively preventing the influence of deformation and vibration on the equipment.

[0008] Compared with the rigid connection between the core and the frame in traditional flat-plate transformers, a flexible fixed connection between the base and the core is achieved by dotting soft glue in the glue dispensing groove. The soft glue has a certain elastic deformation ability and can absorb the stress caused by vibration during vehicle operation to avoid relative displacement of the core and the base during vehicle movement, resulting in core breakage. This improves the defect of traditional rigid connection that the core is prone to breakage during vehicle movement, and improves the overall product life and safety of the transformer from the perspective of yield effect.

[0009] Optionally, the reinforcement component includes a first reinforcing rib, which is fixedly connected to the top surface of the mounting groove, the length direction of the first reinforcing rib is arc-shaped, and the first reinforcing rib is coaxially arranged with the sleeve, and the two ends of the first reinforcing rib in the length direction are respectively fixedly connected to the side walls on both sides of the mounting groove, and a plurality of first reinforcing ribs are provided, and the plurality of first reinforcing ribs are evenly distributed along the radial direction of the sleeve.

[0010] By adopting the above technical solution, the first reinforcing ribs enhance the overall stability of the base and improve the structural strength. The multiple first reinforcing ribs are evenly distributed along the radial direction of the sleeve, ensuring balanced force and further improving the mechanical performance and reliability of the device.

[0011] Optionally, the reinforcement assembly also includes a second reinforcing rib, two of which are provided and are also fixedly connected to the top surface of the mounting groove, the two second reinforcing ribs are respectively arranged on both sides of the sleeve, and the length direction of the second reinforcing rib is the radial direction of the sleeve.

[0012] By adopting the above technical solution, the reinforcement component not only includes the first reinforcing rib, but also adds the second reinforcing rib. The second reinforcing rib is fixedly connected to the top surface of the mounting groove, and is respectively arranged on both sides of the sleeve, and the length direction is the radial direction of the sleeve. This design further enhances the overall stability of the base, especially when subjected to the same force as the length direction of the second reinforcing rib, it can effectively prevent deformation and improve the structural strength and reliability. At the same time, the second reinforcing rib and the first reinforcing rib together form a more stable support structure, making the entire flat transformer more stable and reliable during use.

[0013] Optionally, the second reinforcing rib is located at the center of the first reinforcing rib, and a reinforcement groove is formed between the first reinforcing rib, the second reinforcing rib and the side wall of the mounting groove; when the core seat and the base are spliced ​​together, the glue dispensing groove and the reinforcement groove are connected to each other, and when soft glue is dispensed into the glue dispensing groove, part of the soft glue can flow into the reinforcement groove.

[0014] By adopting the above technical solution, the second reinforcing rib is located at the center of the first reinforcing rib, and together with the side wall of the installation groove, forms a reinforcement groove. When the core seat and the base are spliced, the glue dispensing groove and the reinforcement groove are interconnected, so that during the glue dispensing process, part of the soft glue can flow into the reinforcement groove, thereby further enhancing the overall stability and structural strength of the base and improving the reliability after assembly.

[0015] Optionally, the reinforcement component also includes a third reinforcement rib, and a plurality of the third reinforcement ribs are provided, and the plurality of the third reinforcement ribs are fixedly connected to the side walls of the mounting groove; an inclined block is fixedly provided on the side walls of the mounting groove, and the inclined block is located at the boundary between the reinforcement groove and the glue dispensing groove, and when glue is dispensed into the glue dispensing groove, part of the soft glue can enter the reinforcement groove through the inclined block.

[0016] By adopting the above technical solution, the reinforcement component not only includes the first reinforcement rib and the second reinforcement rib, but also adds a plurality of third reinforcement ribs. These third reinforcement ribs are fixedly connected to the side walls of the mounting groove, further enhancing the overall stability and structural strength of the base, and effectively preventing deformation or damage caused by vibration or impact. At the same time, the third reinforcement ribs together with the first reinforcement ribs, the second reinforcement ribs and the side walls of the mounting groove form a more complex reinforcement network, so that the soft glue can better fill each gap during glue dispensing, thereby improving the sealing performance and reliability of the entire device. The design of the tilting block enables part of the soft glue to flow smoothly into the reinforcement groove during glue dispensing, further enhancing the fixing strength between the core seat and the base, and improving the stability and reliability of the structure.

[0017] Optionally, the height of the wire wrap is adapted to the height of the sleeve, and the height of the magnetic core seat is also adapted to the height of the sleeve. Soft glue can be brushed on the top surfaces on both sides of the magnetic core seat, and the magnetic core plate and the magnetic core seat are fixedly connected by the soft glue on the top surface of the magnetic core seat.

[0018] By adopting the above technical solution, the height of the wire package is matched with the height of the sleeve, ensuring the stability and consistency of the wire package on the sleeve and improving the electromagnetic conversion efficiency. The height of the core seat is also matched with the height of the sleeve, ensuring the good fit between the core seat and the sleeve and enhancing the compactness of the structure. Soft glue can be brushed on the top surface of both sides of the core seat, so that the core plate and the core seat are fixedly connected by the soft glue, which not only increases the connection strength, but also effectively reduces vibration and noise, and improves the reliability and service life of the product.

[0019] In addition, in traditional flat-plate transformers, the connection position between the core seat and the core plate coincides with the height of the wire package. During the connection process after glue dispensing, the soft glue easily overflows onto the wire package. This solution can avoid the soft glue overflowing onto the wire package and interfering with the wire package by unifying the height of the wire package, sleeve and core seat.

[0020] Optionally, the coil package includes a starting coil, a first coil and a second coil; a socket is fixedly connected to the bottom of the outer wall of the sleeve, the socket is annular, and a distance is left between the socket and the top surface of the base, the starting coil is sleeved on the sleeve and located between the socket and the base; the first coil is provided in several groups, the first coil is wound on the sleeve, and the first coil is in a pancake shape; the second coil is provided in several groups, the second coil is also wound on the sleeve, and the second coil is flat.

[0021] By adopting the above technical scheme, the coil structure design of the flat transformer for vehicle-mounted DCAC power supply is reasonable, which is specifically manifested as follows: the starting coil is sleeved on the sleeve and is located between the sleeve seat and the base, ensuring that the initial position of the coil is stable and avoiding the risk of loosening or falling off of the starting section; the first coil and the second coil are respectively in a pancake shape and a flat shape, and are wound on the sleeve, so that the coil distribution is more uniform, reducing electromagnetic interference and improving transmission efficiency; the first coil has a small diameter and is suitable for passing high-voltage current. By winding multiple layers on the same plane to form a pancake structure, the current conduction efficiency is improved and electromagnetic interference is reduced; the second coil is designed in a flat shape, with a wider width and a lower height, which not only meets the needs of low-voltage current transmission, but also can effectively reduce the overall height of the transformer, thereby better controlling the volume of the entire equipment; the design of the sleeve not only increases the support points of the coil, but also prevents the coil from slipping, further enhancing the stability of the entire device.

[0022] Optionally, a gasket is provided between adjacent first coils and second coils, the gasket is annular and is also sleeved on the sleeve, and the gasket is fixedly connected to the first coil and the second coil by soft glue.

[0023] By adopting the above technical solution, the setting of the gasket can effectively reduce the friction and wear between the first coil and the second coil, and improve the service life of the coil; at the same time, the gasket is fixedly connected to the first coil and the second coil by soft glue; in addition, the gasket is a high-temperature gasket, which avoids the degradation of insulation performance due to increased temperature, further enhances the stability and reliability of the structure, and ensures the stable performance of the transformer during operation.

[0024] Optionally, a snap-in groove is provided on one side of the top of the base, and three plug-in interfaces are provided at the bottom of the snap-in groove. The size of the plug-in interfaces is adapted to the size of the second coil, and the end of the second coil away from the sleeve can be inserted into the plug-in interface. Soft glue can also be applied in the snap-in groove to fix the second coil to the base.

[0025] By adopting the above technical solution, the second coil and the base can be reliably fixedly connected during the assembly process. Specifically, the design of the snap-in slot enables the second coil to be accurately inserted into the specified position, and the size of the plug-in interface matches the second coil to ensure positioning accuracy. At the same time, the soft glue in the snap-in slot can further enhance the fixing effect and prevent loosening due to vibration or impact, thereby improving the stability and reliability of the entire flat transformer for vehicle-mounted DCAC power supply. The flexible fixed connection method of the soft glue also provides a certain elastic deformation space between the second coil and the base.

[0026] Optionally, a tin-plated layer is provided at one end of the second coil away from the sleeve, and the tin-plated layer is plated on the second coil. When the second coil is inserted into the plug interface, the tin-plated layer is located below the plug interface. A side of the top of the sleeve away from the clamping groove is fixedly connected to a limiting block. When the wire wrap is sleeved on the sleeve, the wire wrap can be fixedly connected to the limiting block by applying soft glue on the limiting block.

[0027] By adopting the above technical solution, a tin-plated layer is provided at one end of the second coil away from the sleeve, which can facilitate better welding of the second coil with the subsequent PCB board through the tin-plated layer. At the same time, the design of the limit block makes the fixing of the wire package on the sleeve more firm and reliable, preventing the wire package from loosening or falling off, and improving the mechanical strength and service life of the product.

[0028] Compared with the solution of setting limit blocks on both sides of the sleeve, the limit block is fixedly connected only on the side away from the clamping groove, avoiding fixed connection on the side close to the clamping groove. This can give the second coil a certain deformation space and further improve the service life of the product from the perspective of yield effect.

[0029] In summary, the present application includes at least one of the following beneficial technical effects: 1. Through the design of the glue dispensing groove reserved between the core seat and the base and the reinforcement component, a reliable fixed connection between the core seat and the base is achieved, avoiding the problem of core breakage due to shaking during vehicle driving in the traditional rigid connection method, and improving the stability and service life of the product; 2. The glue dispensing groove is connected to the reinforcement groove, so that the soft glue can not only fill the glue dispensing groove, but also flow into the reinforcement groove to further enhance the structural strength, thereby improving the mechanical stability and seismic resistance of the overall device; 3. The setting of the first reinforcing rib and the second reinforcing rib enhances the rigidity of the installation slot, prevents deformation during long-term use, and ensures the long-term stable operation of the transformer; 4. The layered design of the starting coil, the first coil and the second coil on the sleeve makes the coil layout more reasonable, reduces electromagnetic interference and improves electromagnetic compatibility; 5. The design of the card slot and the plug interface facilitates the fixation of the second coil, simplifies the assembly steps, and ensures good contact between the coil and the base, thereby improving the reliability of the electrical connection. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is a schematic diagram of the overall structure of an embodiment of the present application; Figure 2 This is a schematic diagram of the overall structure of the hidden wire package in the embodiment of the present application; Figure 3It is a schematic diagram of the longitudinal section structure of an embodiment of the present application; Figure 4 is a schematic diagram of the structure from the bottom perspective of the skeleton in the embodiment of the present application; Figure 5 This is a schematic diagram of the overall structure of the embodiment of the present application from the bottom perspective; Figure 6 This is a partial structural schematic diagram of the hidden magnetic core portion of an embodiment of the present application; Figure 7 A schematic diagram of the overall structure of an embodiment of the present application from another perspective.

[0031] Explanation of the accompanying drawings: 1. Skeleton; 11. Base; 111. Mounting slot; 112. Snap-in slot; 113. Plug port; 114. Pin; 12. Sleeve; 13. Sleeve seat; 14. Limit block; 2. Magnetic core; 21. Magnetic core seat; 22. Magnetic core plate; 3. Wire package; 31. Starting coil; 32. First coil; 33. Second coil; 331. Tinned layer; 34. Gasket; 35. Lead wire; 4. Adhesive tape; 5. Glue dispensing slot; 6. Soft glue; 7. Reinforcement assembly; 71. First reinforcing rib; 72. Second reinforcing rib; 73. Third reinforcing rib; 74. Reinforcement slot; 75. Tilt block. DETAILED DESCRIPTION

[0032] The following is combined with Figure 1-Figure 7 This application is described in further detail.

[0033] The present application embodiment discloses a flat transformer for a vehicle-mounted DCAC power supply. Figure 1 and Figure 2 A flat-plate transformer for a vehicle-mounted DCAC power supply includes a skeleton 1, a magnetic core 2 and a coil 3; the skeleton 1 includes a base 11 and a sleeve 12, the sleeve 12 is fixedly connected to the top center of the base 11, the base 11 is annular and is coaxially arranged with the sleeve 12, and the coil 3 is sleeved on the sleeve 12.

[0034] Reference Figure 1 and Figure 3 The core part 2 includes a core seat 21 and a core plate 22. The core seat 21 is in a mountain shape. The center of the core seat 21 is adapted to the size of the sleeve 12. The center of the core seat 21 can be inserted into the sleeve 12. The bottom of the core seat 21 can be connected to the base 11. The core plate 22 is arranged on the top of the core seat 21 and can be connected to the core seat 21. The core seat 21 and the core plate 22 are covered with adhesive tape 4. The adhesive tape 4 can further enhance the stability of the core part 2 and ensure that the fixed connection between the core seat 21 and the base 11 and the core plate 22 is more stable and reliable.

[0035] Reference Figure 4 and Figure 5A mounting groove 111 is provided at the bottom of the base 11, and the size of the mounting groove 111 is adapted to the size of the bottom of the core seat 21. When the core seat 21 is installed on the frame 1 and the center of the core seat 21 is inserted into the sleeve 12, a preset distance is left between the core seat 21 and the side wall of the mounting groove 111. The preset distance forms a glue dispensing groove 5, in which soft glue 6 can be dispensed, and the core seat 21 and the base 11 can be fixedly connected by the soft glue 6 in the glue dispensing groove 5; a reinforcement component 7 is also provided in the mounting groove 111, and the reinforcement component 7 is used to strengthen the overall stability of the base 11.

[0036] The flat-plate transformer for vehicle-mounted DCAC power supply has the following effects: the design of the skeleton 1 enables the core seat 21 to be stably installed on the base 11, while ensuring good electrical performance and heat dissipation capabilities; the structural design of the core part 2 enables precise matching between the core seat 21 and the sleeve 12, thereby improving the electromagnetic conversion efficiency; the mounting groove 111 on the base 11 is combined with the glue dispensing groove 5 to ensure a firm connection between the core seat 21 and the base 11, thereby enhancing the stability of the overall structure; the setting of the reinforcement component 7 further enhances the overall strength of the base 11, thereby effectively preventing deformation and vibration from affecting the equipment.

[0037] Compared with the rigid connection between the magnetic core and the frame 1 in the traditional flat transformer, the flexible fixed connection between the base 11 and the magnetic core is achieved by setting the soft glue 6 in the glue dispensing groove 5. The soft glue 6 has a certain elastic deformation ability and can absorb the stress caused by vibration during the operation of the vehicle to avoid the relative displacement of the magnetic core and the base 11 during the movement of the vehicle, which may cause the magnetic core to break. This improves the defect of the traditional rigid connection that the magnetic core is prone to breakage during the movement of the vehicle, and improves the overall product life and safety of the transformer from the perspective of the yield effect.

[0038] Reference Figure 4 The reinforcement component 7 includes a first reinforcing rib 71, which is fixedly connected to the top surface of the mounting groove 111. The length direction of the first reinforcing rib 71 is arc-shaped, and the first reinforcing rib 71 is coaxially arranged with the sleeve 12. The two ends of the first reinforcing rib 71 in the length direction are respectively fixedly connected to the side walls on both sides of the mounting groove 111. There are a plurality of first reinforcing ribs 71, and the plurality of first reinforcing ribs 71 are evenly distributed along the radial direction of the sleeve 12. The setting of the first reinforcing rib 71 enhances the overall stability of the base 11 and improves the structural strength. Multiple first reinforcing ribs 71 are evenly distributed along the radial direction of the sleeve 12, ensuring balanced force and further improving the mechanical performance and reliability of the device.

[0039] Reference Figure 4, the reinforcement component 7 also includes a second reinforcement rib 72, two of which are provided. The second reinforcement rib 72 is also fixedly connected to the top surface of the mounting groove 111, and the two second reinforcement ribs 72 are respectively arranged on both sides of the sleeve 12, and the length direction of the second reinforcement rib 72 is the radial direction of the sleeve 12. The reinforcement component 7 not only includes the first reinforcement rib 71, but also adds the second reinforcement rib 72. The second reinforcement rib 72 is fixedly connected to the top surface of the mounting groove 111, and is respectively arranged on both sides of the sleeve 12, and the length direction is the radial direction of the sleeve 12. This design further enhances the overall stability of the base 11, especially when subjected to a force in the same length direction as the second reinforcement rib 72, it can effectively prevent deformation and improve the structural strength and reliability. At the same time, the second reinforcement rib 72 and the first reinforcement rib 71 together form a more stable support structure, making the entire flat-plate transformer more stable and reliable during use.

[0040] Reference Figure 4 and Figure 5 , the second reinforcing rib 72 is located at the center of the first reinforcing rib 71, and a reinforcing groove 74 is formed between the first reinforcing rib 71, the second reinforcing rib 72 and the side wall of the installation groove 111; when the magnetic core seat 21 and the base 11 are spliced ​​together, the glue dispensing groove 5 and the reinforcing groove 74 are interconnected, and when the soft glue 6 is dispensed into the glue dispensing groove 5, part of the soft glue 6 can flow into the reinforcing groove 74. The second reinforcing rib 72 is located at the center of the first reinforcing rib 71, and together with the side wall of the installation groove 111, a reinforcing groove 74 is formed. When the magnetic core seat 21 and the base 11 are spliced ​​together, the glue dispensing groove 5 and the reinforcing groove 74 are interconnected, so that during the glue dispensing process, part of the soft glue 6 can flow into the reinforcing groove 74, thereby further enhancing the overall stability and structural strength of the base 11 and improving the reliability after assembly.

[0041] Reference Figure 4 and Figure 5 , the reinforcement component 7 also includes a third reinforcement rib 73, and a plurality of the third reinforcement ribs 73 are provided, and the plurality of third reinforcement ribs 73 are fixedly connected to the side wall of the mounting groove 111. The reinforcement component 7 includes not only the first reinforcement rib 71 and the second reinforcement rib 72, but also a plurality of third reinforcement ribs 73. These third reinforcement ribs 73 are fixedly connected to the side wall of the mounting groove 111, further enhancing the overall stability and structural strength of the base 11, and effectively preventing deformation or damage caused by vibration or impact. At the same time, the third reinforcement rib 73, the first reinforcement rib 71, the second reinforcement rib 72 and the side wall of the mounting groove 111 together form a more complex reinforcement network, so that the soft glue 6 can better fill each gap when dispensing, thereby improving the sealing performance and reliability of the entire device.

[0042] Reference Figure 4 and Figure 5A tilting block 75 is fixedly arranged on the side wall of the mounting groove 111. The tilting block 75 is located at the boundary between the reinforcement groove 74 and the glue dispensing groove 5. When dispensing glue into the glue dispensing groove 5, part of the soft glue 6 can enter the reinforcement groove 74 through the tilting block 75. The design of the tilting block 75 enables part of the soft glue 6 to flow smoothly into the reinforcement groove 74 during the glue dispensing process, further enhancing the fixing strength between the magnetic core seat 21 and the base 11, and improving the stability and reliability of the structure.

[0043] Reference Figure 2 and Figure 3 , the height of the wire package 3 is adapted to the height of the sleeve 12, and the height of the core seat 21 is also adapted to the height of the sleeve 12. Soft glue 6 can be brushed on the top surfaces on both sides of the core seat 21, and the core plate 22 and the core seat 21 are fixedly connected through the soft glue 6 on the top surface of the core seat 21. The height of the wire package 3 is adapted to the height of the sleeve 12, which ensures the stability and consistency of the wire package 3 on the sleeve 12 and improves the electromagnetic conversion efficiency. The height of the core seat 21 is also adapted to the height of the sleeve 12, which ensures the good fit between the core seat 21 and the sleeve 12 and enhances the compactness of the structure. Soft glue 6 can be brushed on the top surfaces on both sides of the core seat 21, so that the core plate 22 and the core seat 21 are fixedly connected through the soft glue 6, which not only increases the connection strength, but also effectively reduces vibration and noise, and improves the reliability and service life of the product.

[0044] In addition, in the traditional flat-plate transformer, the connection position between the core seat 21 and the core plate 22 coincides with the height of the wire coil 3. During the connection process after glue dispensing, the soft glue 6 is easy to overflow onto the wire coil 3. This solution can avoid the soft glue 6 overflowing onto the wire coil 3 and interfering with the wire coil 3 by unifying the height of the wire coil 3, the sleeve 12 and the core seat 21.

[0045] Reference Figure 2 and Figure 3 The coil 3 includes a starting coil 31, a first coil 32 and a second coil 33; a sleeve seat 13 is fixedly connected to the bottom of the outer wall of the sleeve 12, the sleeve seat 13 is annular, and a distance is left between the sleeve seat 13 and the top surface of the base 11, the starting coil 31 is sleeved on the sleeve 12 and is located between the sleeve seat 13 and the base 11; the first coil 32 is provided in a plurality of groups, the first coil 32 is wound on the sleeve 12, and the first coil 32 is in a pancake shape; the second coil 33 is provided in a plurality of groups, the second coil 33 is also wound on the sleeve 12, and the second coil 33 is flat.

[0046] The coil 3 of the flat transformer for vehicle-mounted DCAC power supply has a reasonable structural design, which is specifically manifested as follows: the starting coil 31 is sleeved on the sleeve 12 and is located between the sleeve 13 and the base 11, ensuring that the initial position of the coil 3 is stable and avoiding the risk of loosening or falling off of the starting section; the first coil 32 and the second coil 33 are respectively pancake-shaped and flat, and are wound on the sleeve 12, so that the coil distribution is more uniform, reducing electromagnetic interference and improving transmission efficiency; the first coil 32 has a small diameter and is suitable for passing high-voltage current. By winding multiple layers on the same plane to form a pancake-shaped structure, the current conduction efficiency is improved and electromagnetic interference is reduced; the second coil 33 is designed to be flat, with a wider width and a lower height, which not only meets the requirements of low-voltage current transmission, but also can effectively reduce the overall height of the transformer, thereby better controlling the volume of the entire equipment; the design of the sleeve 13 not only increases the support points of the coil 3, but also prevents the coil 3 from slipping, further enhancing the stability of the entire device.

[0047] Reference Figure 3 , a gasket 34 is provided between each adjacent first coil 32 and second coil 33, the gasket 34 is annular and is also sleeved on the sleeve 12, and the gasket 34 is fixedly connected to the first coil 32 and the second coil 33 through the soft glue 6. The setting of the gasket 34 can effectively reduce the friction and wear between the first coil 32 and the second coil 33, and improve the service life of the coil; at the same time, the gasket 34 is fixedly connected to the first coil 32 and the second coil 33 through the soft glue 6; in addition, the gasket 34 is a high-temperature gasket 34, which avoids the decrease of insulation performance due to temperature increase, further enhances the stability and reliability of the structure, and ensures the stable performance of the transformer during operation.

[0048] Reference Figure 1 and Figure 6 A snap-in slot 112 is provided on one side of the top of the base 11, and three plug-in ports 113 are provided at the bottom of the snap-in slot 112. The size of the plug-in port 113 matches the size of the second coil 33. The end of the second coil 33 away from the sleeve 12 can be inserted into the plug-in port 113. Soft glue 6 can also be arranged in the snap-in slot 112 to fix the second coil 33 to the base 11. The design of the snap-in slot 112 enables the second coil 33 to be accurately inserted into the specified position, and the size of the plug-in port 113 matches the second coil 33 to ensure positioning accuracy. At the same time, the soft glue 6 arranged in the snap-in slot 112 can further enhance the fixing effect and prevent loosening caused by vibration or impact, thereby improving the stability and reliability of the entire flat transformer for vehicle-mounted DCAC power supply. In addition, the flexible fixed connection method of the soft glue 6 also provides a certain elastic deformation space between the second coil 33 and the base 11.

[0049] Reference Figure 5 and Figure 7, four pins 114 are provided on one side of the base 11 away from the clamping groove 112, and two leads 35 are provided on one end of the starting coil 31 away from the sleeve 12 and one end of the first coil 32 away from the sleeve 12, and the two leads 35 of the starting coil 31 and the two leads 35 of the first coil 32 are respectively wound around the two pins 114; Figure 3 The first coil 32 has three layers in the vertical direction, and the second coil 33 has four layers in the vertical direction.

[0050] Reference Figure 6 and Figure 7 A tinned layer 331 is provided at one end of the second coil 33 away from the sleeve 12, and the tinned layer 331 is plated on the second coil 33. When the second coil 33 is inserted into the plug port 113, the tinned layer 331 is located below the plug port 113; a side of the top of the sleeve 12 away from the clamping groove 112 is fixedly connected to the limiting block 14. When the wire package 3 is sleeved on the sleeve 12, the wire package 3 can be fixedly connected to the limiting block 14 by applying soft glue 6 on the limiting block 14.

[0051] A tin-plated layer 331 is provided at one end of the second coil 33 away from the sleeve 12, so that the second coil 33 can be better welded to the subsequent PCB board through the tin-plated layer 331. At the same time, the design of the limit block 14 makes the fixation of the wire package 3 on the sleeve 12 more firm and reliable, prevents the wire package 3 from loosening or falling off, and improves the mechanical strength and service life of the product. Compared with the solution of providing the limit blocks 14 on both sides of the sleeve 12, the limit block 14 is fixedly connected only on the side away from the snap-in groove 112, avoiding the fixed connection on the side close to the snap-in groove 112, which can give the second coil 33 a certain deformation space, and further improve the service life of the product from the perspective of the yield effect.

[0052] The implementation principle of a flat-plate transformer for a vehicle-mounted DCAC power supply in the embodiment of the present application is as follows: Before assembly, cut the sleeve first. Before cutting, confirm whether the material specifications meet the requirements. Confirm the length to be cut, and then adjust the length on the equipment. After cutting, the sleeve is not damaged, the cut is smooth, and there is no obvious deformation.

[0053] During assembly, the lead wire 35 of the starting coil 31 is inserted into the sleeve, the lead wire 35 at the head end is first wound around one of the pins 114, the starting coil 31 is sleeved between the sleeve 13 and the base 11, and the lead wire 35 at the tail end is sleeved on the second pin 114; then glue is applied on both sides of the top of the sleeve 13, and the first layer of the second coil 33 is sleeved and bonded to the top of the sleeve 13; glue is applied on the top of the first layer of the second coil 33, and the first layer of high-temperature gasket 34 is sleeved and bonded to the top of the first layer of the second coil 33; on the first layer of high-temperature gasket Glue is dispensed on the top of the first layer of high temperature gasket 34 to sleeve the first coil 32 of the first layer and bond it to the top of the first layer of high temperature gasket 34; glue is dispensed on the top of the first layer of high temperature gasket 32 ​​to sleeve the second layer of high temperature gasket 34 and bond it to the top of the first layer of high temperature gasket 32; glue is dispensed on the top of the second layer of high temperature gasket 34 to sleeve the second coil 33 of the second layer and bond it to the top of the second layer of high temperature gasket 34; glue is dispensed on the top of the second layer of high temperature gasket 33 to sleeve the third layer of high temperature gasket 34 and bond it to the top of the second layer of high temperature gasket 34; glue is dispensed on the top of the second layer of high temperature gasket 33 to sleeve the third layer of high temperature gasket 34 and bond it to the top of the second layer of high temperature gasket 33; Glue is dispensed on the top of the high-temperature gasket 34, and the top of the second-layer first coil 32 is sleeved and bonded to the top of the third high-temperature gasket 34; glue is dispensed on the top of the second-layer first coil 32, and the fourth-layer high-temperature gasket 34 is sleeved and bonded to the top of the second-layer first coil 32; glue is dispensed on the top of the fourth-layer high-temperature gasket 34, and the third-layer second coil 33 is sleeved and bonded to the top of the fourth-layer high-temperature gasket 34; glue is dispensed on the top of the fourth-layer high-temperature gasket 34, and the fifth-layer high-temperature gasket 34 is sleeved and bonded to the top of the third-layer second coil 33; Glue is dispensed on the top of the third-layer second coil 33, and the sixth-layer high-temperature gasket 34 is sleeved and bonded on the top of the third-layer second coil 33; glue is dispensed on the sixth-layer high-temperature gasket 34, and the third-layer first coil 32 is sleeved and bonded on the top of the sixth-layer high-temperature gasket 34; glue is dispensed on the top of the third-layer first coil 32, and the seventh-layer high-temperature gasket 34 is sleeved and bonded on the top of the third-layer first coil 32; glue is dispensed on the top of the seventh-layer high-temperature gasket 34, and the fourth-layer second coil 33 is sleeved and bonded on the top of the seventh-layer high-temperature gasket 34. During assembly, it is noted that the first coil 32, the second coil 33, the starting coil 31 and the high-temperature gasket 34 must all be coaxially arranged with the sleeve 12. When assembling the second coil 33, the end of the second coil 33 away from the sleeve 12 is inserted into the plug interface 113.

[0054] Glue is dispensed at the limit block 14, and the top of the second coil 33 is bonded to the sleeve 12 through the limit block 14; glue is dispensed in the clamping groove 112, so that the clamping groove 112 must have two-thirds of the glue volume, and the end of the second coil 33 away from the sleeve 12 is bonded to the base 11 through the soft glue 6 in the clamping groove 112; the transformer is placed on the conveyor belt of the tunnel oven to enter the drying, and after the required time is reached, it is placed in a ventilated place to cool for 0.5-2 hours until the glue is completely solidified; the two leads 35 of the first coil 32 are inserted into the sleeve, and the two leads 35 of the first coil 32 are respectively wound around Set it on the third and fourth pins 114; straighten the lead 35 wrapped around the pin 114, and place it on the heating platform and use a special scraper to scrape off the insulation skin; after peeling, wrap the lead 35 back to the previous pin 114; put it on the pin cutting machine for pin cutting; solder high-temperature tin to the bottom of the first coil 32 and the starting coil 31, and solder low-temperature tin to the bottom of the second coil 33; brush glue on the top surface of the core seat 21; insert the center of the core seat 21 into the sleeve 12, and bond the core plate 22 to the top of the core seat 21; set and bond the tape 4 outside the core seat 21 and the core plate 22; perform inductance test; bake again and clean the tin slag.

[0055] Finally, glue is dispensed in the glue dispensing groove 5 between the core seat 21 and the base 11, and part of the soft glue 6 enters the reinforcement groove 74 through the glue dispensing groove 5 and the tilting block 75, and the core seat 21 and the base 11 are bonded and fixed, and then dried and moisture controlled, and then subsequent trimming, testing and packaging are carried out.

[0056] The above are all preferred embodiments of the present application, and the protection scope of the present application is not limited thereto. Therefore, any equivalent changes made according to the structure, shape, and principle of the present application should be included in the protection scope of the present application.

Claims

1. A flat transformer for vehicle-mounted DCAC power supply, characterized in that: The invention comprises a frame (1), a magnetic core part (2) and a wire package (3); the frame (1) comprises a base (11) and a sleeve (12); the sleeve (12) is fixedly connected to the top center of the base (11); the base (11) is annular and is coaxially arranged with the sleeve (12); the wire package (3) is sleeved on the sleeve (12); the magnetic core part (2) comprises a magnetic core seat (21) and a magnetic core plate (22); the magnetic core seat (21) is in a mountain shape; the center of the magnetic core seat (21) is adapted to the size of the sleeve (12); the center of the magnetic core seat (21) can be inserted into the sleeve (12); the bottom of the magnetic core seat (21) can be connected to the base (11); the magnetic core plate (22) is arranged at the top of the magnetic core seat (21) and can be connected to the magnetic core seat (21); The bottom of the base (11) is provided with a mounting groove (111), the size of the mounting groove (111) is adapted to the size of the bottom of the magnetic core seat (21), when the magnetic core seat (21) is mounted on the frame (1), and the center of the magnetic core seat (21) is inserted into the sleeve (12), a preset distance is left between the magnetic core seat (21) and the side wall of the mounting groove (111), the preset distance forms a glue dispensing groove (5), soft glue (6) can be dispensed in the glue dispensing groove (5), and the magnetic core seat (21) and the base (11) can be fixedly connected by the soft glue (6) in the glue dispensing groove (5); a reinforcement component (7) is also provided in the mounting groove (111), and the reinforcement component (7) is used to enhance the overall stability of the base (11).

2. The flat-plate transformer for vehicle-mounted DCAC power supply according to claim 1, characterized in that: The reinforcement component (7) comprises a first reinforcing rib (71), wherein the first reinforcing rib (71) is fixedly connected to the top surface of the mounting groove (111), the length direction of the first reinforcing rib (71) is arc-shaped, and the first reinforcing rib (71) is coaxially arranged with the sleeve (12), and the two ends of the first reinforcing rib (71) in the length direction are respectively fixedly connected to the side walls on both sides of the mounting groove (111), and a plurality of the first reinforcing ribs (71) are provided, and the plurality of the first reinforcing ribs (71) are evenly distributed along the radial direction of the sleeve (12).

3. The flat-plate transformer for vehicle-mounted DCAC power supply according to claim 2, characterized in that: The reinforcement component (7) further comprises a second reinforcement rib (72), two of which are provided. The second reinforcement rib (72) is also fixedly connected to the top surface of the mounting groove (111), the two second reinforcement ribs (72) are respectively arranged on both sides of the sleeve (12), and the length direction of the second reinforcement rib (72) is the radial direction of the sleeve (12).

4. The flat-plate transformer for vehicle-mounted DCAC power supply according to claim 3, characterized in that: The second reinforcing rib (72) is located at the center of the first reinforcing rib (71), and a reinforcing groove (74) is formed between the first reinforcing rib (71), the second reinforcing rib (72) and the side wall of the mounting groove (111); when the magnetic core seat (21) and the base (11) are spliced, the glue dispensing groove (5) and the reinforcing groove (74) are connected to each other, and when soft glue (6) is dispensed into the glue dispensing groove (5), part of the soft glue (6) can flow into the reinforcing groove (74).

5. The flat-plate transformer for vehicle-mounted DCAC power supply according to claim 4, characterized in that: The reinforcement component (7) further comprises a third reinforcement rib (73), wherein a plurality of the third reinforcement ribs (73) are provided, and the plurality of the third reinforcement ribs (73) are fixedly connected to the side wall of the mounting groove (111); an inclined block (75) is fixedly provided on the side wall of the mounting groove (111), and the inclined block (75) is located at the boundary between the reinforcement groove (74) and the glue dispensing groove (5), and when glue is dispensed into the glue dispensing groove (5), part of the soft glue (6) can enter the reinforcement groove (74) through the inclined block (75).

6. The flat-plate transformer for vehicle-mounted DCAC power supply according to claim 1, characterized in that: The height of the wire package (3) is matched with the height of the sleeve (12), and the height of the magnetic core seat (21) is also matched with the height of the sleeve (12). Soft glue (6) can be brushed on the top surfaces of both sides of the magnetic core seat (21), and the magnetic core plate (22) and the magnetic core seat (21) are fixedly connected by the soft glue (6) on the top surface of the magnetic core seat (21).

7. The flat-plate transformer for vehicle-mounted DCAC power supply according to claim 6, characterized in that: The wire package (3) comprises a starting coil (31), a first coil (32) and a second coil (33); a sleeve seat (13) is fixedly connected to the bottom of the outer wall of the sleeve (12); the sleeve seat (13) is annular, and a distance is left between the sleeve seat (13) and the top surface of the base (11); the starting coil (31) is sleeved on the sleeve (12) and is located between the sleeve seat (13) and the base (11); the first coil (32) is provided with a plurality of groups, the first coil (32) is wound on the sleeve (12), and the first coil (32) is in a pancake shape; the second coil (33) is provided with a plurality of groups, the second coil (33) is also wound on the sleeve (12), and the second coil (33) is flat.

8. The flat-plate transformer for vehicle-mounted DCAC power supply according to claim 7, characterized in that: A gasket (34) is provided between adjacent first coils (32) and second coils (33); the gasket (34) is annular and is also sleeved on the sleeve (12); the gasket (34) is fixedly connected to the first coil (32) and the second coil (33) via soft rubber (6).

9. The flat-plate transformer for vehicle-mounted DCAC power supply according to claim 8, characterized in that: A snap-in groove (112) is provided on one side of the top of the base (11), and three plug-in ports (113) are provided at the bottom of the snap-in groove (112). The size of the plug-in ports (113) matches the size of the second coil (33), and one end of the second coil (33) away from the sleeve (12) can be inserted into the plug-in port (113). Soft glue (6) can also be arranged in the snap-in groove (112) for fixedly connecting the second coil (33) to the base (11).

10. The flat-plate transformer for vehicle-mounted DCAC power supply according to claim 9, characterized in that: A tinned layer (331) is provided at one end of the second coil (33) away from the sleeve (12), and the tinned layer (331) is plated on the second coil (33). When the second coil (33) is inserted into the plug interface (113), the tinned layer (331) is located below the plug interface (113). A side of the top of the sleeve (12) away from the clamping groove (112) is fixedly connected to a limit block (14). When the wire package (3) is sleeved on the sleeve (12), the wire package (3) can be fixedly connected to the limit block (14) by applying soft glue (6) on the limit block (14).

Images