Low-loss high-frequency transformer based on nanocrystalline alloy

Abstract

The invention discloses a low-loss high-frequency transformer based on nanocrystalline alloy, and belongs to the technical field of transformers, the low-loss high-frequency transformer comprises a mounting plate, an n-shaped framework, a columnar magnetic core, a winding and a protective heat dissipation mechanism, the columnar magnetic core is of a three-column type composite structure and is formed by staggering and laminating nanocrystalline thin film layers and ferrite sheet layers, a stepped air gap structure and an insulating isolation layer are arranged on the outer surface; and the winding leading-out end is connected with an external circuit through symmetrically distributed plug connectors. The protective heat dissipation mechanism is composed of an epoxy layer containing boron nitride filler, a heat conduction ring, heat dissipation fins, a heat dissipation fan and a flow guide plate. The advantages of nanocrystalline and ferrite materials are combined, a composite heat dissipation system is matched, the magnetic core loss under the high-frequency working condition is remarkably reduced, temperature rise is effectively controlled, the insulation performance and assembly stability are improved, low-loss, high-efficiency and high-stability operation is achieved, and the requirements of the fields of new energy automobiles, photovoltaic energy storage and the like are met.

Description

Technical Field

[0001] This invention relates to the field of transformer technology, specifically to a low-loss high-frequency transformer based on nanocrystalline alloys. Background Technology

[0002] With the rapid development of new energy vehicles, photovoltaic energy storage, and communication power supplies, the market has placed stringent demands on high-frequency transformers, requiring low loss, miniaturization, high efficiency, and high reliability. Existing high-frequency transformers mostly use silicon steel or a single ferrite core, which is prone to problems such as high hysteresis loss and unstable permeability under high-frequency operating conditions. At the same time, traditional winding and core assembly precision is low, and the heat dissipation structure has insufficient heat dissipation efficiency, resulting in limited overall transformer efficiency, larger size, and difficulty in adapting to high-density power conversion scenarios.

[0003] Among the publicly disclosed patent technologies, some solutions have attempted to use nanocrystalline materials or optimize heat dissipation structures, but significant limitations remain: The nanocrystalline transformer for an inverter welding machine (publication number CN203491056U) uses a non-cut nanocrystalline magnetic ring. While it reduces costs through enameled aluminum wire, it lacks a core composite structure design and a multi-component collaborative high-efficiency heat dissipation mechanism, resulting in limited high-frequency loss and temperature rise control. The open-type dry transformer (publication number CN102945741B) focuses on fixing the windings through a frame and impregnation process, but fails to optimize material combinations for core losses under high-frequency conditions or design a targeted heat dissipation solution, making it difficult to meet the low-loss requirements of high-power-density scenarios. The high-frequency transformer heat dissipation structure (publication number CN111292929B) only improves the heat dissipation process from the outside of the casting body, failing to form a multi-path heat conduction system from the windings to the environment, resulting in low heat dissipation efficiency. The shortcomings are as follows: The high-frequency transformer ferrite core in announcement number CN212587330U uses a ferrite core with a limiting block to fix the coil. The core material itself has higher high-frequency losses than nanocrystalline materials, and the single structure makes it difficult to quickly dissipate the heat accumulated in the core components, limiting operational stability. The nanocrystalline magnetic ring transformer in announcement number CN203491056U reduces losses by winding the core with ultra-thin strip, but the coil material selection and heat dissipation structure design are relatively simple, failing to consider the synergistic optimization of core loss suppression and efficient heat dissipation of the whole machine. The open-type transformer in announcement number CN102945741B uses an iron-based nanocrystalline core and air insulation design, which improves insulation recovery, but it does not use a composite core stacking structure or a precise air gap to control magnetic flux density, leaving room for improvement in high-frequency losses and adaptability.

[0004] Furthermore, some existing patents, such as the one in publication number CN106700427B, while improving the thermal conductivity of the casting material by adding boron nitride, do not optimize the core material combination; the LLC magnetic integrated high-frequency transformer in publication number CN116612960B uses a ferrite core and annular copper strip winding to enhance heat dissipation, but does not employ a composite core structure and precise air gap design. These patents generally have technical shortcomings: either the core uses a single material, failing to combine the advantages of different soft magnetic materials to further reduce losses; or the heat dissipation structure design is simple, failing to form a complete system of multi-component coordinated heat conduction and dissipation; or the integrated design of insulation protection and component positioning is not taken into account, leading to assembly deviations that cause leakage flux or insulation risks. These problems make it difficult for existing high-frequency transformers to simultaneously meet the comprehensive requirements of low loss, high heat dissipation efficiency, and high insulation reliability, and cannot fully adapt to the stringent application scenarios of high-density power conversion in the new energy field. Summary of the Invention

[0005] The purpose of this invention is to provide a low-loss high-frequency transformer based on nanocrystalline alloys to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A low-loss high-frequency transformer based on nanocrystalline alloy includes: a mounting plate, a U-shaped frame fixedly mounted on the upper surface of the mounting plate, a columnar magnetic core fixedly mounted inside the U-shaped frame, the columnar magnetic core having a three-column structure, a winding fitted on the outer surface of each set of columnar magnetic cores, and a protective heat dissipation mechanism fitted on the outer surface of the three sets of windings.

[0007] The aforementioned low-loss high-frequency transformer based on nanocrystalline alloys, wherein: the columnar magnetic core is a composite magnetic core structure, which is composed of alternating layers of nanocrystalline thin film and ferrite sheet, with adjacent nanocrystalline thin film layers and ferrite sheet layers forming a stacking unit, and multiple stacking units are sequentially stacked to form the complete columnar magnetic core.

[0008] The aforementioned low-loss high-frequency transformer based on nanocrystalline alloys includes an insulating layer tightly bonded to the outer surface of the columnar magnetic core. The insulating layer is made of polyimide film with a thickness of 0.05 to 0.1 mm, which is used to achieve insulation protection between the columnar magnetic core and the winding.

[0009] The aforementioned low-loss high-frequency transformer based on nanocrystalline alloy, wherein: the lead-out terminals of each group of windings are electrically connected to corresponding connectors, and electrical conduction with the input / output circuits of external devices is achieved through the connectors; the three groups of connectors are evenly distributed along the height direction of the columnar magnetic core and are symmetrically arranged about the central axis of the U-shaped frame; each group of connectors respectively positions and fixes the top, middle and bottom of the U-shaped frame, and simultaneously allows the three groups of windings to connect to the input and output circuits of the corresponding devices.

[0010] The aforementioned low-loss high-frequency transformer based on nanocrystalline alloys includes a stepped air gap structure on the outer surface of each set of columnar magnetic cores. The magnetic flux density of the air gap structure at 20 kHz is less than or equal to 0.2 Tesla, resulting in an overall efficiency of the high-frequency transformer greater than or equal to 96%, and a core iron loss of less than 3.4 watts per kilogram at 20 kHz / 0.2 Tesla.

[0011] The aforementioned low-loss high-frequency transformer based on nanocrystalline alloy includes: a protective heat dissipation mechanism comprising an epoxy layer, the epoxy layer being sleeved on the outer surface of the winding; connecting blocks being fixedly installed on both the upper and lower surfaces of the epoxy layer, and being fitted to the upper and lower surfaces of the U-shaped frame through the connecting blocks; the two ends of the outer surfaces of the three sets of epoxy layers being fixedly installed between two sets of U-shaped plates by bolts; the U-shaped plates being fixedly installed at both ends of the outer surface of the U-shaped frame; and boron nitride filler being added to the epoxy layer to increase the thermal conductivity of the epoxy layer to 0.8 to 1.2 watts per meter Kelvin.

[0012] In the aforementioned low-loss high-frequency transformer based on nanocrystalline alloy, a heat-conducting ring is fitted onto the outer surface of the epoxy layer, and heat dissipation fins are fixedly installed on the outer surface of the heat-conducting ring at equal intervals.

[0013] In the aforementioned low-loss high-frequency transformer based on nanocrystalline alloy, a cooling fan is correspondingly provided at the lower end of the heat-conducting ring. The cooling fan is fixedly installed in the mounting port through the housing on its outer surface, and the mounting port is opened on the mounting plate.

[0014] In the aforementioned low-loss high-frequency transformer based on nanocrystalline alloy, a flow guide plate is fixedly installed on the outer periphery of the upper surface of the mounting plate, and the flow guide plate surrounds the upper end of the outer surface of the cooling fan.

[0015] The aforementioned low-loss high-frequency transformer based on nanocrystalline alloy includes: a dust filter at the air inlet of the cooling fan; a high-emissivity heat dissipation coating sprayed on the surface of the heat dissipation fins; and the emissivity of the high-emissivity heat dissipation coating being greater than or equal to 0.85, which is used to improve the radiative heat dissipation efficiency of the heat dissipation fins.

[0016] Compared with the prior art, the beneficial effects of the present invention are: 1. The columnar magnetic core adopts a composite structure of alternating nanocrystalline thin film layers and ferrite sheet layers, combined with a stepped air gap structure, which fully utilizes the advantages of the two materials, suppresses magnetic saturation, significantly reduces the energy loss of the magnetic core under high-frequency operating conditions, improves the magnetic permeability of the magnetic core, and lays the core foundation for low-loss operation of transformers.

[0017] 2. The protective heat dissipation mechanism, through the synergistic effect of epoxy layer, heat conduction ring, heat dissipation fins and cooling fan, plus the airflow guidance of the baffle plate, quickly absorbs and dissipates the heat generated during transformer operation, effectively controls the temperature rise of the whole machine, avoids the impact of high temperature on equipment performance, and ensures the long-term stable operation of the transformer.

[0018] 3. The polyimide film insulation layer between the cylindrical magnetic core and the winding, combined with the insulation properties of the epoxy layer, significantly improves the insulation protection performance of the transformer, blocks unexpected conductive paths, avoids the risk of insulation breakdown under high-frequency and high-voltage conditions, and ensures the safe operation of the equipment.

[0019] 4. The connectors are evenly distributed along the height of the cylindrical magnetic core and symmetrically arranged about the central axis of the U-shaped frame. This ensures the reliability of the connection between the winding and the external circuit, and also realizes the all-round positioning and fixation of the U-shaped frame, reducing the leakage magnetic problem caused by assembly deviation and improving the stability and efficiency of power conversion.

[0020] 5. Each component adopts a modular assembly design with a reasonable structural layout, adapting to different specifications of high-frequency power conversion scenarios, enhancing the product's versatility and application flexibility, and meeting the stringent requirements of high-frequency transformers in fields such as new energy vehicles, photovoltaic energy storage, and communication power supplies. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the columnar magnetic core and winding of the present invention; Figure 3 This is a schematic diagram of the structure of the U-shaped plate of the present invention; Figure 4 This is a schematic diagram of the stepped air gap structure on the outer surface of the columnar magnetic core of the present invention. Figure 5 This is a schematic diagram of the protective heat dissipation mechanism of the present invention.

[0022] In the diagram: 1. U-shaped frame; 101. Mounting plate; 102. Guide plate; 103. Mounting port; 104. Columnar magnetic core; 105. U-shaped plate; 106. Winding; 2. Protective heat dissipation mechanism; 201. Connecting block; 202. Epoxy layer; 203. Thermal ring; 204. Heat dissipation fins; 205. Cooling fan. Detailed Implementation

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] Please see Figures 1-5 This embodiment provides a low-loss high-frequency transformer based on nanocrystalline alloy, including: a mounting plate 101, a U-shaped frame 1 fixedly mounted on the upper surface of the mounting plate 101, and columnar magnetic cores 104 fixedly mounted inside the U-shaped frame 1. The columnar magnetic cores 104 have a three-column structure, and windings 106 are fitted on the outer surface of each set of columnar magnetic cores 104. A protective heat dissipation mechanism 2 is fitted on the outer surface of the three sets of windings 106. The mounting plate 101 provides a stable mounting foundation for the transformer as a whole, the U-shaped frame 1 achieves precise positioning and fixation of the columnar magnetic cores 104, and the three-column columnar magnetic cores 104 and windings 106 cooperate to form the core structure for power conversion. The protective heat dissipation mechanism 2 can dissipate the heat generated during operation, forming a stable and functional high-frequency transformer basic architecture, providing structural support for subsequent low-loss and high-efficiency operation.

[0025] Specifically, in this embodiment, the columnar magnetic core 104 is a composite magnetic core structure, composed of alternating layers of nanocrystalline thin films and ferrite sheet layers. Adjacent nanocrystalline thin film layers and ferrite sheet layers form a stacking unit, and multiple stacking units are sequentially stacked to form a complete columnar magnetic core 104. The columnar magnetic core 104 adopts a composite structure of alternating layers of nanocrystalline thin films and ferrite sheet layers, which fully combines the characteristics of low hysteresis loss and high permeability of nanocrystalline materials with the advantages of high insulation of ferrite materials. This effectively reduces the energy loss of the magnetic core under high-frequency operating conditions, improves the magnetic permeability of the magnetic core, and provides core material support for low-loss operation of transformers.

[0026] Specifically, in this embodiment, an insulating layer is tightly bonded to the outer surface of the columnar magnetic core 104. This insulating layer is made of polyimide film with a thickness of 0.05 to 0.1 mm, and is used to achieve insulation protection between the columnar magnetic core 104 and the winding 106. The polyimide film insulating layer bonded to the outer surface of the columnar magnetic core 104 can reliably isolate the columnar magnetic core 104 from the winding 106, blocking unintended conductive paths between them, avoiding the risk of insulation breakdown under high-frequency, high-voltage conditions, strengthening the insulation protection performance of the transformer, and ensuring safe equipment operation.

[0027] Specifically, in this embodiment, the lead-out ends of each winding 106 are electrically connected to corresponding connectors, enabling electrical conduction with the input / output circuits of external devices. The three connectors are evenly distributed along the height of the cylindrical magnetic core 104 and symmetrically arranged about the central axis of the U-shaped frame 1. Each connector corresponds to the positioning and fixing of the top, middle, and bottom of the U-shaped frame 1, while also allowing the three windings 106 to connect to the input and output circuits of the corresponding devices. The windings 106 are electrically connected to the external circuits through the connectors, achieving stable conduction of electrical energy input and output. The even distribution of the connectors along the height of the cylindrical magnetic core 104 and their symmetrical arrangement about the central axis of the U-shaped frame 1 ensures the reliability of the connection between the windings 106 and the external circuits, while also providing omnidirectional positioning and fixing of the top, middle, and bottom of the U-shaped frame 1, reducing magnetic leakage caused by assembly deviations and improving the stability of power conversion.

[0028] Specifically, in this embodiment, the outer surface of each set of columnar magnetic cores 104 is provided with a stepped air gap structure. The magnetic flux density of the air gap structure at 20 kHz is less than or equal to 0.2 Tesla, resulting in an overall efficiency of the high-frequency transformer greater than or equal to 96%, and a core iron loss of less than 3.4 watts per kilogram at 20 kHz / 0.2 Tesla. The stepped air gap structure on the outer surface of the columnar magnetic cores 104 can reasonably control the magnetic flux density distribution in the magnetic circuit, suppress magnetic saturation, reduce the additional losses caused by magnetic saturation, optimize the magnetic permeability of the core, and provide magnetic circuit design assurance for the efficient operation of the transformer.

[0029] Specifically, in this embodiment, the protective heat dissipation mechanism 2 includes an epoxy layer 202, which is sleeved on the outer surface of the winding 106. Connecting blocks 201 are fixedly installed on both the upper and lower surfaces of the epoxy layer 202, and are assembled to the upper and lower surfaces of the U-shaped frame 1 through the connecting blocks 201. The two ends of the outer surfaces of the three sets of epoxy layers 202 are fixedly installed between two sets of U-shaped plates 105 by bolts. The U-shaped plates 105 are fixedly installed at both ends of the outer surface of the U-shaped frame 1. Boron nitride filler is added to the epoxy layer 202 to increase the thermal conductivity of the epoxy layer 202 to 0.8 to 1.2 watts per meter Kelvin. The addition of boron nitride filler to the epoxy layer 202 in the protective heat dissipation mechanism 2 improves its thermal conductivity, enabling it to quickly absorb the heat generated by the winding 106. The connecting block 201 and the U-shaped plate 105 work together to achieve a stable assembly of the epoxy layer 202 and the U-shaped frame 1, preventing structural loosening during heat dissipation from affecting thermal conductivity stability. At the same time, the epoxy layer 202 also has an insulating protection function, further enhancing the insulation performance of the equipment and providing dual protection for efficient heat dissipation and insulation.

[0030] Specifically, in this embodiment, a thermally conductive ring 203 is fitted onto the outer surface of the epoxy layer 202, and heat dissipation fins 204 are fixedly installed on the outer surface of the thermally conductive ring 203 at equal intervals. The thermally conductive ring 203 on the outer surface of the epoxy layer 202 can evenly distribute the heat conducted by the epoxy layer 202, and the heat dissipation fins 204 arranged at equal intervals on its outer surface increase the contact area between heat and air, accelerate the dissipation of heat to the surrounding environment, improve the efficiency of heat transfer and dissipation, and help control the temperature rise of the transformer.

[0031] Specifically, in this embodiment, a cooling fan 205 is correspondingly provided at the lower end of the heat-conducting ring 203. The cooling fan 205 is fixedly installed in the mounting port 103 through the housing on its outer surface. The mounting port 103 is opened on the mounting plate 101. The cooling fan 205 at the lower end of the heat-conducting ring 203 is fixed in the mounting port 103 of the mounting plate 101. After starting, it can accelerate the surrounding air circulation, so that the airflow can quickly sweep the surface of the heat dissipation fins 204, and promptly remove the heat accumulated on the heat dissipation fins 204, enhance the heat dissipation effect, and prevent heat from accumulating inside the equipment and causing excessive temperature rise.

[0032] Specifically, in this embodiment, a guide plate 102 is fixedly installed on the outer periphery of the upper surface of the mounting plate 101, and the guide plate 102 surrounds the upper part of the outer surface of the cooling fan 205. The guide plate 102 on the mounting plate 101 surrounds the upper part of the outer surface of the cooling fan 205, which can guide the airflow generated by the cooling fan 205 to flow in a directional manner, avoid airflow turbulence that reduces heat dissipation efficiency, ensure that the airflow accurately acts on the area of ​​the heat dissipation fins 204, and ensure the stable and efficient operation of the heat dissipation system.

[0033] Specifically, in this embodiment, the air inlet of the cooling fan 205 is equipped with a dust filter, and the surface of the heat dissipation fins 204 is coated with a high-emissivity heat dissipation coating. The emissivity of the high-emissivity heat dissipation coating is greater than or equal to 0.85, which is used to improve the radiative heat dissipation efficiency of the heat dissipation fins 204. The dust filter at the air inlet of the cooling fan 205 can prevent dust in the air from entering the equipment, avoiding dust from adhering to the surface of heat dissipation components or electrical components and affecting performance and heat dissipation effect; the high-emissivity heat dissipation coating on the surface of the heat dissipation fins 204 can enhance the radiative heat dissipation capacity, further improve the heat dissipation efficiency, and at the same time extend the service life of equipment components, ensuring the long-term stable operation of the transformer.

[0034] Working principle: Mounting plate 101 provides a stable bearing foundation for the entire transformer. The U-shaped frame 1 precisely limits and fixes the internal three-column columnar magnetic core 104, ensuring the relative position stability of each component. Winding 106 is fitted onto the outer surface of the columnar magnetic core 104. When energized, it generates an alternating magnetic field, magnetizing the columnar magnetic core 104. The columnar magnetic core 104 employs a composite structure of alternating nanocrystalline thin film layers and ferrite sheet layers, combining the advantages of low hysteresis loss and high permeability of nanocrystalline materials with the high insulation of ferrite materials. Combined with its stepped air gap structure on the outer surface, it can rationally control the magnetic flux density distribution, suppress magnetic saturation, improve the core's magnetic permeability, and reduce core energy loss. Through the magnetic flux coupling of the columnar magnetic core 104, the electrical energy conversion between the primary and secondary windings 106 is realized, completing voltage rise / fall and power transmission.

[0035] The polyimide film insulation layer between the columnar magnetic core 104 and the winding 106 blocks unintended conductive paths between them, preventing insulation breakdown under high-frequency and high-voltage conditions. In the protective heat dissipation mechanism 2, the addition of boron nitride filler to the epoxy layer 202 improves its thermal conductivity, quickly absorbing the heat generated by the winding 106 and the columnar magnetic core 104. The heat-conducting ring 203 evenly distributes the heat conducted by the epoxy layer 202 to the heat dissipation fins 204, increasing the contact area between heat and air and accelerating heat dissipation. After the cooling fan 205 starts, it accelerates airflow and quickly removes the heat from the heat dissipation fins 204. The air guide plate 102 guides the airflow in a directional manner, ensuring heat dissipation and effectively controlling the overall temperature rise. The winding 106 is electrically connected to the external circuit through connectors. The symmetrical distribution design of the connectors ensures connection reliability and reduces leakage magnetic problems caused by assembly deviations, improving the stability of power conversion.

[0036] How to use: 1. The entire transformer is fixedly assembled into the target equipment cabinet by mounting plate 101, ensuring that mounting plate 101 stably supports U-shaped frame 1 and keeps the relative positions of each component stable.

[0037] 2. Connect the leads of the three windings 106 to the input and output circuits of the external device respectively through the corresponding connectors. Use the connectors to realize the electrical conduction between the windings 106 and the external circuit. At the same time, use the connectors to complete the all-round positioning and fixation of the top, middle and bottom of the U-shaped frame 1.

[0038] 3. When the external power supply is connected, the transformer starts to work. The winding 106 is energized to energize the cylindrical magnetic core 104, and the conversion and transmission of electrical energy are completed through the magnetic flux coupling of the cylindrical magnetic core 104.

[0039] 4. During transformer operation, the protective heat dissipation mechanism 2 automatically functions. The epoxy layer 202, heat conduction ring 203, heat dissipation fins 204 and cooling fan 205 work together to dissipate heat. The guide plate 102 guides the airflow in a directional manner to ensure heat dissipation efficiency. The dust filter at the air inlet of the cooling fan 205 prevents dust from entering the equipment and avoids affecting the performance of the components.

[0040] 5. When the equipment is not in use, first disconnect the external power supply, and then disconnect the winding 106 from the external circuit as needed, or keep it in the assembled state for the next use.

[0041] In summary, this low-loss high-frequency transformer based on nanocrystalline alloy has the following technical advantages: 1. The columnar magnetic core 104 adopts a composite structure of alternating nanocrystalline thin film layers and ferrite sheet layers, combined with a stepped air gap structure, which fully utilizes the advantages of the two materials, suppresses magnetic saturation, significantly reduces the energy loss of the magnetic core under high-frequency operating conditions, improves the magnetic permeability of the magnetic core, and lays the core foundation for low-loss operation of transformers.

[0042] 2. The protective heat dissipation mechanism 2, through the synergistic effect of the epoxy layer 202, the heat-conducting ring 203, the heat dissipation fins 204 and the cooling fan 205, plus the airflow guidance of the guide plate 102, quickly absorbs and dissipates the heat generated during the operation of the transformer, effectively controls the temperature rise of the whole machine, avoids the impact of high temperature on the performance of the equipment, and ensures the long-term stable operation of the transformer.

[0043] 3. The polyimide film insulation layer between the columnar magnetic core 104 and the winding 106, combined with the insulation properties of the epoxy layer 202, significantly improves the insulation protection performance of the transformer, blocks unexpected conductive paths, avoids the risk of insulation breakdown under high-frequency and high-voltage conditions, and ensures the safe operation of the equipment.

[0044] 4. The connectors are evenly distributed along the height of the cylindrical magnetic core 104 and symmetrically arranged about the central axis of the U-shaped frame 1. This ensures the reliability of the connection between the winding 106 and the external circuit, and also realizes the all-round positioning and fixation of the U-shaped frame 1, reducing the leakage magnetic problem caused by assembly deviation and improving the stability and efficiency of power conversion.

[0045] 5. Each component adopts a modular assembly design with a reasonable structural layout, adapting to different specifications of high-frequency power conversion scenarios, enhancing the product's versatility and application flexibility, and meeting the stringent requirements of high-frequency transformers in fields such as new energy vehicles, photovoltaic energy storage, and communication power supplies.

[0046] All parts not described in this invention are the same as or can be implemented using existing technology. Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A low-loss high-frequency transformer based on nanocrystalline alloy, characterized in that, include: Mounting plate (101), the upper surface of which is fixedly mounted with a U-shaped frame (1), the U-shaped frame (1) is fixedly mounted with a columnar magnetic core (104), the columnar magnetic core (104) is a three-column structure, the outer surface of each group of columnar magnetic cores (104) is fitted with a winding (106), and the outer surface of the three groups of windings (106) is fitted with a protective heat dissipation mechanism (2).

2. The low-loss high-frequency transformer based on nanocrystalline alloy according to claim 1, characterized in that: The columnar magnetic core (104) is a composite magnetic core structure, which is composed of alternating layers of nanocrystalline thin film and ferrite sheet. Adjacent nanocrystalline thin film layers and ferrite sheet layers form a stacking unit, and multiple stacking units are stacked sequentially to form the complete columnar magnetic core (104).

3. The low-loss high-frequency transformer based on nanocrystalline alloy according to claim 2, characterized in that: An insulating layer is tightly attached to the outer surface of the columnar magnetic core (104). The insulating layer is made of polyimide film with a thickness of 0.05 to 0.1 mm and is used to achieve insulation protection between the columnar magnetic core (104) and the winding (106).

4. A low-loss high-frequency transformer based on nanocrystalline alloy according to claim 3, characterized in that: The lead-out ends of each winding (106) are electrically connected to the corresponding connectors, and the connectors enable electrical connection with the input / output circuits of external devices. The three connectors are evenly distributed along the height direction of the columnar magnetic core (104) and are symmetrically arranged about the central axis of the U-shaped frame (1). Each connector is used to position and fix the top, middle and bottom of the U-shaped frame (1), and at the same time, the three windings (106) are connected to the input and output circuits of the corresponding devices.

5. A low-loss high-frequency transformer based on nanocrystalline alloy according to claim 3, characterized in that: The outer surface of each columnar magnetic core (104) is provided with a stepped air gap structure. The magnetic flux density of the air gap structure is ≤0.2T under 20kHz operating conditions, which makes the overall efficiency of the high-frequency transformer ≥96%, and the core iron loss is <3.4W / kg under 20kHz / 0.2T operating conditions.

6. A low-loss high-frequency transformer based on nanocrystalline alloy according to claim 1, characterized in that: The protective heat dissipation mechanism (2) includes an epoxy layer (202), which is sleeved on the outer surface of the winding (106). Connecting blocks (201) are fixedly installed on the upper and lower surfaces of the epoxy layer (202), and are assembled to the upper and lower surfaces of the U-shaped frame (1) through the connecting blocks (201). The two ends of the outer surfaces of the three sets of epoxy layers (202) are fixedly installed between two sets of U-shaped plates (105) by bolts. The U-shaped plates (105) are fixedly installed at both ends of the outer surface of the U-shaped frame (1). Boron nitride filler is added to the epoxy layer (202) to increase the thermal conductivity of the epoxy layer (202) to 0.8~1.2W / m·K.

7. A low-loss high-frequency transformer based on nanocrystalline alloy according to claim 6, characterized in that: A heat-conducting ring (203) is fitted on the outer surface of the epoxy layer (202), and heat dissipation fins (204) are fixedly installed on the outer surface of the heat-conducting ring (203) at equal intervals.

8. A low-loss high-frequency transformer based on nanocrystalline alloy according to claim 7, characterized in that: A cooling fan (205) is provided at the lower end of the heat-conducting ring (203). The cooling fan (205) is fixedly installed in the mounting port (103) through the housing on its outer surface. The mounting port (103) is opened on the mounting plate (101).

9. A low-loss high-frequency transformer based on nanocrystalline alloy according to claim 8, characterized in that: A guide plate (102) is fixedly installed on the outer periphery of the upper surface of the mounting plate (101), and the guide plate (102) surrounds the upper end of the outer surface of the cooling fan (205).

10. A low-loss high-frequency transformer based on nanocrystalline alloy according to claim 9, characterized in that: The air inlet of the cooling fan (205) is provided with a dust filter, and the surface of the heat dissipation fins (204) is coated with a high-radiation heat dissipation coating. The emissivity of the high-radiation heat dissipation coating is ≥0.85, which is used to improve the radiation heat dissipation efficiency of the heat dissipation fins (204).

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