Transformer, on-board charger, electric drive system, and vehicle

Abstract

To provide a transformer, an on-board charger, an electric drive system, and a vehicle, in which a thermally conductive potting glue can be easily inserted into the interior of the transformer to improve thermal conductivity performance in order to meet high-power application scenarios.SOLUTION: A transformer 100 includes: a core 10 encapsulated in a thermally conductive potting glue and including a frame portion and a central pillar; a coil 20 wound around the central pillar; and a holder 30 including a shaft portion that encases the central pillar so as to be positioned between the coil and the central pillar, wherein a first fluid channel for the thermally conductive potting glue to flow through is provided between the shaft portion and the central pillar, and the shaft portion includes a second fluid channel that allows the thermally conductive potting glue to flow from the first fluid channel through the shaft portion to the coil.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a transformer. The present disclosure further relates to an on-board charger including such a transformer, an electric drive system including the on-board charger, and a vehicle including the electric drive system. [Background technology]

[0002] Vehicles typically include multiple transformers to supply different voltages to different electrical components. The coils and cores of the transformers generate a large amount of heat during continuous operation. A known method for improving the heat dissipation capacity of a transformer is to encapsulate the transformer in thermally conductive potting glue so that the heat generated by the transformer is efficiently conducted to an external heat dissipation system. However, the transformer's core is hermetically held in a holder with a closed surface, and the coil is tightly wound in multiple layers on the holder. The thermally conductive potting glue can only penetrate from the outside to the inside of the transformer, but struggles to penetrate the inside of the transformer. In particular, it is difficult for the thermally conductive potting glue to fill the gaps between the holder and the core, the gaps between the holder and the coil, and the gaps between the coils in the inner layers. Therefore, it is difficult to improve the thermal conduction performance inside the transformer, and the generated heat accumulates inside the transformer, causing an increase in temperature, which affects the reliability and performance of the transformer.

[0003] Therefore, there is an urgent need for a transformer that facilitates the entry of thermally conductive potting glue into the interior of the transformer to improve heat transfer performance in order to suit high power application scenarios. Summary of the Invention

[0004] The purpose of the present disclosure is to propose a transformer to solve the above-mentioned technical problems, which has multiple fluid channels to facilitate the flow of thermally conductive potting glue into the inside of the transformer, and therefore has good heat transfer performance and can be used in high-power application scenarios.

[0005] The above-mentioned objects are achieved by a transformer according to one embodiment of the present disclosure, the transformer including: a core including a frame portion and a central pillar; a coil wound around the central pillar; and a holder including a shaft portion that encases the central pillar such that the shaft portion is located between the coil and the central pillar. A first fluid channel for flowing thermally conductive potting glue therethrough is provided between the shaft portion and the central pillar, and the shaft portion includes a second fluid channel that allows the thermally conductive potting glue to flow from the first fluid channel through the shaft portion to the coil.

[0006] An object of the present disclosure is to provide a transformer configured to facilitate the flow of thermally conductive potting glue into the interior of the transformer to achieve good thermal conductivity suitable for high-power application scenarios. The transformer according to the present disclosure includes a first fluid channel disposed between the shank of the holder and the central post of the core, and a second fluid channel disposed in and passing through the shank of the holder. Thus, the thermally conductive potting glue can flow through the first fluid channel into the region between the shank of the holder and the central post of the core, filling any gaps between the holder and the core. The thermally conductive potting glue can also flow from the first fluid channel through the shank to the coil to fill any gaps between the holder and the coil. Additionally, the thermally conductive potting glue flowing through the shank to the coil can permeate from the shank of the holder into the coil to fill any gaps between the coil inner layers. Therefore, the transformer according to the present disclosure allows the thermally conductive potting glue to completely fill the gaps inside the transformer, thereby improving the thermal conductivity performance inside the transformer, efficiently conducting the heat generated by the transformer to the outside of the transformer, and eliminating heat accumulation to suit high-power application scenarios.

[0007] A transformer according to the present disclosure may also have one or more of the following features, either individually or in combination:

[0008] According to one embodiment of the present disclosure, the stem includes a third fluid channel that allows thermally conductive potting glue to flow from the outside to the region between the stem and the coil, so that the gap between the stem of the holder and the coil can also be filled by the thermally conductive potting glue flowing through the third fluid channel.

[0009] According to one embodiment of the present disclosure, the first fluid channel includes a concave or protruding structure disposed on a surface of the shank facing the central pillar, which may separate the central pillar and the shank by a specific distance to form the first fluid channel.

[0010] According to one embodiment of the present disclosure, the second fluid channel includes a first through-hole extending through the stem, and the thermally conductive potting glue can flow through the first through-hole.

[0011] According to one embodiment of the present disclosure, the third fluid channel is formed by a penetration formed inside the coil.

[0012] According to one embodiment of the present disclosure, the shank includes protrusions extending from a surface of the shank facing the coils, the protrusions separating the coils to form the feedthrough.

[0013] According to one embodiment of the present disclosure, the stem includes a second through-hole connecting the penetration and the first fluid channel, allowing the thermally conductive potting glue to flow from the penetration to the first fluid channel through the second through-hole, which is particularly useful for transformers with long first fluid channels.

[0014] According to one embodiment of the present disclosure, the stem includes a protrusion extending from a surface of the stem facing the coil, the third fluid channel being formed within the protrusion.

[0015] According to one embodiment of the present disclosure, the holder further includes a wiring portion, the wiring portion including a wiring terminal, and the coil is electrically connected to the wiring terminal.

[0016] According to one embodiment of the present disclosure, the coil includes a first coil and a second coil, the holder includes a first holder and a second holder, the first holder includes a first shaft portion located between the first coil and the central pillar, the second holder includes a second shaft portion located between the second coil and the central pillar, the first holder further includes a first mating portion, and the second holder further includes a second mating portion, the first mating portion mating with the second mating portion such that the first holder and the second holder are coupled to form the holder.

[0017] According to one embodiment of the present disclosure, the first mating portion is a joint slot and the second mating portion is a joint protrusion that can be joined to the joint slot, or the second mating portion is a joint slot and the first mating portion is a joint protrusion that can be joined to the joint slot.

[0018] According to one embodiment of the present disclosure, the central pillar includes a first central pillar and a second central pillar, the first coil is wound around the first central pillar, the second coil is wound around the second central pillar, and the first and second central pillars are aligned with and adjacent to each other to form the central pillar.

[0019] The present disclosure further relates to an on-board charger including the transformer described above.

[0020] The present disclosure further relates to an electric drive system including the on-board charger described above.

[0021] The present disclosure further relates to a vehicle including the on-board charger or electric drive system described above.

[0022] The foregoing and other features and advantages of the present disclosure will become more apparent from the following detailed description of exemplary embodiments with reference to the accompanying drawings, wherein the description and accompanying drawings are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way. The following drawings are not to scale according to actual dimensions, but rather focus on illustrating the main object of the present disclosure. [Brief explanation of the drawings]

[0023] [Figure 1] FIG. 1 is a 3D schematic diagram of a transformer according to the present disclosure. [Figure 2A] FIG. 1 illustrates a core of a transformer according to the present disclosure showing the assembled core. [Figure 2B] FIG. 10 illustrates a core of a transformer according to the present disclosure, showing the core with the second central post omitted. [Figure 2C] FIG. 10 illustrates a transformer core according to the present disclosure showing a second central pillar. [Figure 3A] 1 illustrates a transformer holder according to the present disclosure showing the holder assembled. [Figure 3B] 1 illustrates a holder for a transformer according to the present disclosure, showing a first holder. [Figure 3C] 10A and 10B illustrate a holder for a transformer according to the present disclosure showing a second holder. [Figure 4] FIG. 1 is a cross-sectional view of a transformer according to the present disclosure showing multiple fluid channels for a thermally conductive potting glue. [Figure 5] FIG. 1 is a side view of a transformer according to the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0024] In order to make the objectives, technical solutions and advantages of the embodiments of the present disclosure clear, the technical solutions of the embodiments of the present disclosure are clearly and completely described below in conjunction with the drawings of the embodiments of the present disclosure.

[0025] Unless otherwise specified, technical or scientific terms used herein shall have the common meaning as understood by one of ordinary skill in the art to which this disclosure belongs. The terms "one," "a," or "the" used in the description and claims of the patent applications disclosed herein do not denote a limitation of quantity, but rather denote the presence of at least one. The terms "comprising" or "including" and similar terms mean that the elements or objects appearing before the term encompass the elements or objects listed thereafter and their equivalents. While terms such as "first" and "second" are used to describe various components of the present disclosure, they are intended only to distinguish one component from another, rather than to limit the order or importance of the corresponding components. A "first element" may be described as a "second element," and similarly, a "second element" may be described as a "first element," without departing from the scope of the present disclosure. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but may include electrical connections, whether direct or indirect. The terms "upper," "lower," "left," "right," and the like are used only to indicate relative positions, and if the absolute positions of the symmetries described change, the relative positions may change accordingly.

[0026] For ease of explanation, the drawings in the present disclosure therefore simplify or omit components commonly used in the technical field, such as external connecting lines and other components that are not relevant to the description of the present disclosure, and these omitted or simplified components will not affect the understanding of the contents of the present disclosure by those skilled in the art.

[0027] 1 illustrates a transformer 100 according to an exemplary embodiment of the present disclosure. Transformer 100 may be a component of, for example, a vehicle's on-board charger, where the component is used for voltage conversion, receiving an input voltage and converting it to an output voltage via electromagnetic induction. For example, transformer 100 may receive a 220V or 380V power supply voltage and convert it to high-voltage AC, which, when rectified, can charge the vehicle's battery. Alternatively, transformer 100 may receive inverted high-voltage AC from the battery and convert it to a 220V or 380V power supply voltage for use as an external power source for the vehicle.

[0028] As shown in FIG. 1, the transformer 100 includes a core 10, a coil 20, and a holder 30. The holder 30 includes a wiring portion 36 with wiring terminals 360. The wiring terminals 360 have the form of electrode plates, and multiple wiring terminals 360 are located on the same side of the transformer 100. Such an arrangement allows the transformer 100 to be easily connected to an external connection member. Specifically, when the external connection member is a printed circuit board, holes positioned and sized to accommodate insertion of the wiring terminals 360 can be formed in the printed circuit board. Thus, the transformer 100 can be connected to the printed circuit board by insertion. The coil 20 is electrically connected to the wiring terminals 360, and receives an input voltage or outputs an output voltage converted by the transformer 100 via the wiring terminals 360.

[0029] 2A to 2C show the core 10 of the transformer 100. Referring to FIGS. 2A to 2C, the core 10 includes a frame portion 11 and a central pillar 12. The central pillar 12 includes a first central pillar 12a and a second central pillar 12b aligned with and disposed adjacent to the first central pillar 12a. The first central pillar 12a is integral with the frame portion 11, and the second central pillar 12b can be fastened to the first central pillar 12a to form the core 10.

[0030] 1 in conjunction with FIG. 4, the coils 20 of the transformer 100 are wound around the central post 12 of the core 10, and include a first coil 20a wound around the first central post 12a and a second coil 20b wound around the second central post 12b. The first coil 20a and the second coil 20b can function as a primary coil that receives an input voltage and a secondary coil that outputs a converted input voltage, respectively.

[0031] 3A to 3C show the holder 30 of the transformer 100. Referring to FIGS. 3A to 3C in conjunction with FIGS. 1 and 4, the holder 30 includes a shaft portion 31. In the assembled structure of the transformer 100, the shaft portion 31 is located between the coil 20 and the central pillar 12 and surrounds the central pillar 12. Specifically, the holder 30 includes a first holder 30a and a second holder 30b that are connected together. The first holder 30a includes a first mating portion 37a in the form of a mating slot, and the second holder 30b includes a second mating portion 37b in the form of a mating protrusion. When assembling the transformer 100, the mating protrusion of the second mating portion 37b is mated with the mating slot of the first mating portion 37a to form the holder 30. Optionally, the first mating portion 37a can be formed as a joining protrusion and the second mating portion 37b can be formed as a joining slot. Further optionally, the first mating portion 37a and the second mating portion 37b can also have other shapes that can mate with each other to connect the first holder 30a to the second holder 30b.

[0032] 3B and 3C in conjunction with FIG. 4, the first holder 30a includes a first shaft portion 31a, which is located between the first coil 20a and the first core post 12a and surrounds the first core post 12a in the assembled structure of the transformer 100. The second holder 30b includes a second shaft portion 31b, which is located between the second coil 20b and the second core post 12b and surrounds the second core post 12b in the assembled structure of the transformer 100. When assembling the transformer 100, the second core post 12b can first be accommodated in the second shaft portion 31b of the second holder 30b and wound with the second coil 20b, and the second holder 30b can then be joined to the first holder 30a.

[0033] During operation of the transformer 100, the coil 20 and the core 10 may generate a large amount of heat. This heat needs to be conducted to an external heat dissipation device to prevent overheating and failure within the transformer 100. For high-power transformers 100, the heat conduction performance inside such transformers 100 is particularly important. For example, when it is necessary to improve the charging performance of a vehicle, the output of the transformer in a high-power on-board charger must be increased accordingly. The transformer 100 according to the present disclosure has a novel structure that allows the thermally conductive potting glue for encapsulating the transformer to completely penetrate all of the transformer components and fill any voids that may exist inside the transformer. These voids can have a significant adverse effect on the thermal conduction performance of the transformer 100. As a result of using the thermally conductive potting glue to fill these voids, the transformer 100 according to the present disclosure has good heat conduction performance, and therefore, the output power can be increased.

[0034] 4 and the side view shown in FIG. 5, a transformer 100 according to the present disclosure includes a plurality of fluid channels. Thermally conductive potting glue can flow through these fluid channels into internal locations within the transformer 100, including locations between the stem 31 of the holder 30 and the central post 12 of the core 10, between the stem 31 and the coil 20, and the like. Thus, the thermally conductive potting glue can permeate outward from these internal locations, such as into the interior of the coil 20. This outward permeation of the thermally conductive potting glue, combined with the inward permeation of the thermally conductive potting glue from the outside into the transformer 100, allows the thermally conductive potting glue to fully penetrate all of the components of the transformer 100 and fill any voids that may exist.

[0035] Specifically, the fluid channel includes a first fluid channel 41 disposed between the stem 31 (including the first stem 31a and / or the second stem 31b) of the holder 30 and the central pillar 12 of the core 10. The first fluid channel 41 may be formed by concave or protruding structures 32 disposed on the surface of the stem 31 facing the central pillar 12. These concave or protruding structures 32 may include insulating ribs formed on the inner surface of the stem 31, or other structures adapted to separate the stem 31 from the central pillar 12. The concave or protruding structures 32 may separate the stem 31 and the central pillar 12 by a certain gap so that the thermally conductive potting glue flows through them. Referring to Figure 5, the first fluid channel 41 is connected to the outside at the two outer ends of the transformer 100, so that the thermally conductive potting glue can flow from the outside into the transformer 100 through the first fluid channel 41 to fill the gap between the shaft portion 31 and the central pillar 12.

[0036] The fluid channel also includes a second fluid channel 42 disposed in the stem 31 of the holder 30 and passing through the stem 31 (including the first stem 31 a and / or the second stem 31 b). The thermally conductive potting glue in the first fluid channel 41 can flow through the stem 31 via the second fluid channel 42 to the coil 20, specifically to the inner layer of the coil 20. Referring to FIG. 4 , the coil 20 is made up of multiple coil layers. The thermally conductive potting glue flowing through the second fluid channel 42 to the inner layer can permeate outward through voids in the coil 20, and the thermally conductive potting glue from the outside can permeate inward from the outer layer of the coil 20 through voids in the coil 20, in this way completely filling the voids in the coil 20. As illustrated, the stem 31 of the holder 30 includes a first through-hole 33 extending therethrough, and the second fluid channel 42 may be formed by the first through-hole 33. Referring to Figures 3A-3C in conjunction with Figure 4, the stem 31 may include a plurality of first through-holes 33 in a honeycomb arrangement, thereby forming a plurality of second fluid channels 42 such that the thermally conductive potting glue can flow through the stem 31 from all positions on the stem 31. It should be readily understood that the thermally conductive potting glue in the second fluid channels 42 may also fill any gaps between the coil 20 and the stem 31.

[0037] The fluid channels further include a third fluid channel 43 through which the thermally conductive potting glue can flow from the outside to the region between the shank 31 and the coil 20. Referring to FIGS. 3A-3C in conjunction with FIG. 4, the shank 31 of the holder 30 includes a protrusion 34 extending (i.e., extending outward) from the surface of the shank 31 facing the coil 20. The protrusion 34 separates the coil 20 and forms a through-hole 21 inside the coil 20. The third fluid channel 43 can be formed by the through-hole 21. The shank 31 also includes a second through-hole 35 connecting the through-hole 21 and the first fluid channel 41. The thermally conductive potting glue can therefore flow through the second through-hole 35 into the first fluid channel 41. This is particularly beneficial for a transformer 100 in which the shank 31 of the holder 30 is long. As shown in FIGS. 3B and 4, the first fluid channel 41 formed between the first shaft 31a and the first core post 12a is long due to the long length of the first shaft 31a of the first holder 30a. The thermally conductive potting glue flowing into the first fluid channel 41 from the two outer ends of the transformer 100 has difficulty flowing to the middle of the first fluid channel 41. As a result of providing the protrusion 34 at the middle of the first shaft 31a, the first coil 20a is separated in the length direction of the shaft 31 (i.e., in the direction of extension of the first fluid channel 41), thus forming the through-hole 21. Furthermore, the second through-hole 35 allows the thermally conductive potting glue to flow directly from the outside through the third fluid channel 43 to the middle of the first fluid channel 41, thereby shortening the flow path to the middle. This can prevent a region without thermally conductive potting glue from occurring in the middle of the first fluid channel 41. It should be readily understood that the thermally conductive potting glue in the third fluid channel 43 can also penetrate into the interior of the coil 20 on two sides.

[0038] In the embodiment shown in the drawings, the second shank 31b of the second holder 30b has a short length and does not include a protrusion forming a penetration. In an optional embodiment not depicted in the drawings, a protrusion forming a penetration may also be provided on the second shank 31b of the second holder 30b.

[0039] Optionally, the protrusion 34 of the stem 31 of the holder 30 may be hollow. The thermally conductive potting glue may flow from the outside through the hollow protrusion 34 to the region between the stem 31 and the coil 20. That is, a third fluid channel 43 may be formed within the protrusion 34.

[0040] According to another aspect of the present disclosure, an electric drive system is proposed that includes the on-board charger described above.

[0041] According to another aspect of the present disclosure, there is proposed a vehicle including the on-board charger or electric drive system described above. The vehicle may be an electrified vehicle, such as a battery electric vehicle (BEV), a hybrid electric vehicle (HEV), a plug-in hybrid electric vehicle (PHEV), or a long-range electric vehicle (long-range EV).

[0042] The particular features, structures, or characteristics in one or more embodiments of the present disclosure may be combined in any suitable manner.

[0043] The above is a description of the present disclosure and should not be considered as limiting thereof. Although several exemplary embodiments of the present disclosure have been described, those skilled in the art will readily appreciate that many modifications can be made to the exemplary embodiments without departing from the inherent teachings and advantages of the present disclosure. Accordingly, all such modifications are intended to be included within the scope of the present disclosure as defined by the claims. The above is a description of the present disclosure and the present disclosure should not be considered limited to the particular embodiments disclosed, and it should be understood that modifications to the disclosed embodiments and other embodiments are intended to be included within the scope of the present disclosure.

Claims

1. A transformer (100), a core (10) including a frame portion (11) and a central pillar (12); a coil (20) wound around the central pillar (12); a holder (30) including a shaft portion (31), the shaft portion (31) enveloping the central pillar (12) so that the shaft portion (31) is located between the coil (20) and the central pillar (12); The invention is characterized in that it comprises A transformer (100) in which a first fluid channel (41) for flowing thermally conductive potting glue therethrough is provided between the stem (31) and the central pillar (12), and the stem (31) has a second fluid channel (42) that allows the thermally conductive potting glue to flow from the first fluid channel (41) through the stem (31) to the coil.

2. 2. The transformer (100) of claim 1, wherein the shaft (31) comprises a third fluid channel (43) that allows the thermally conductive potting glue to flow from the outside to the region between the shaft (31) and the coil (20).

3. 3. The transformer (100) according to claim 1 or 2, characterized in that the first fluid channel (41) includes a concave or protruding structure (32) arranged on a surface of the stem (31) facing the central pillar (12).

4. 3. The transformer (100) according to claim 1 or 2, characterized in that the second fluid channel (42) comprises a first through-hole (33) passing through the stem (31).

5. 3. The transformer (100) according to claim 2, characterized in that the third fluid channel (43) is formed by a penetration (21) formed inside the coil (20).

6. 6. The transformer (100) according to claim 5, wherein the shaft portion (31) has a protrusion (34) extending from a surface of the shaft portion (31) facing the coil (20), the protrusion (34) separating the coil (20) to form the through portion (21).

7. 6. The transformer (100) according to claim 5, characterized in that the shank (31) comprises a second through-hole (35) connecting the penetration (21) and the first fluid channel (41).

8. 3. The transformer (100) according to claim 2, wherein the shaft (31) comprises a protrusion (34) extending from a surface of the shaft (31) facing the coil (20), and the third fluid channel (43) is formed in the protrusion (34).

9. 3. The transformer (100) according to claim 1 or 2, characterized in that the holder (30) further includes a wiring portion (36), the wiring portion (36) having a wiring terminal (360), and the coil (20) is electrically connected to the wiring terminal (360).

10. The coil (20) includes a first coil (20a) and a second coil (20b), The holder (30) includes a first holder (30a) and a second holder (30b), the first holder (30a) includes a first shaft portion (31a) located between the first coil (20a) and the central pillar (12), and the second holder (30b) includes a second shaft portion (31b) located between the second coil (20b) and the central pillar (12), 3. The transformer (100) according to claim 1 or 2, wherein the first holder (30a) further includes a first mating portion (37a), and the second holder (30b) further includes a second mating portion (37b), the first mating portion (37a) mating with the second mating portion (37b) such that the first holder (30a) and the second holder (30b) are coupled to form the holder (30).

11. The first fitting portion (37a) is a joining slot, and the second fitting portion (37b) is a joining protrusion that can be joined to the joining slot; or 11. The transformer (100) according to claim 10, wherein the second mating portion (37b) is a mating slot, and the first mating portion (37a) is a mating protrusion that can be mated to the mating slot.

12. 11. The transformer (100) of claim 10, wherein the core pillar (12) includes a first core pillar (12a) and a second core pillar (12b), the first coil (20a) is wound around the first core pillar (12a) and the second coil (20b) is wound around the second core pillar (12b), and the first core pillar (12a) and the second core pillar (12b) are aligned with and adjacent to each other to form the core pillar (12).

13. An on-board charger, characterized in that it includes a transformer (100) according to any one of claims 1 to 12.

14. An electric drive system including the on-board charger of claim 13.

15. A vehicle comprising an on-board charger according to claim 13 or an electric drive system according to claim 14.

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