Magnetic device and voltage conversion device

Abstract

The application discloses a magnetic device and a voltage conversion device, which comprise a framework, a wire cake and a copper bar winding installed in the framework, and a magnetic core installed on the framework. The copper bar winding comprises a plurality of copper bar winding pieces which are arranged at intervals with the wire cake. The connecting ends of both ends of at least one copper bar winding piece are provided with heat dissipation feet. The heat dissipation feet are connected with the shell of the magnetic device through heat-conducting materials. The heat dissipation feet are arranged at the edges of the connecting ends of the copper bar winding pieces, and the heat dissipation feet are connected with the shell of the magnetic device through heat-conducting materials. The heat of the copper bar winding which is a heat source of the magnetic device can be transmitted through heat conduction. The heat dissipation efficiency of directly leading out the heat of the heat source is high, and is far superior to the heat conduction mode in the prior art. Meanwhile, the copper bar winding is designed as a single-piece structure, which is beneficial to assembly and cost control.

Description

Technical Field

[0001] This invention relates to the field of charging technology and voltage conversion for pure electric and hybrid vehicles, and particularly to magnetic components and voltage conversion devices for on-board chargers (OBC), voltage converters (DCDC), and related integrated products. Background Technology

[0002] With the increasing need for energy conservation, emission reduction, and air pollution control, new energy vehicles are gradually being commercialized, with electric vehicles being the mainstay. Electric vehicles are further divided into pure electric vehicles and hybrid electric vehicles, with on-board chargers (OBCs) and voltage converters (DC converters) being crucial components. Currently, the common heat dissipation solution for magnetic components in OBCs, DC converters, and related integrated products involves fixing the magnetic components to a housing and adding thermally conductive material between the magnetic core and the housing for heat dissipation. However, heat is conducted through the magnetic core, while the non-heat-generating copper busbar windings themselves conduct heat directly. Therefore, the heat dissipation effect is poor, and this solution cannot meet the heat dissipation requirements of the magnetic components. Summary of the Invention

[0003] In order to solve the technical problem of poor heat dissipation of magnetic devices in the prior art, the present invention proposes a magnetic device and a voltage conversion device.

[0004] The technical solution adopted in this invention is:

[0005] This invention proposes a magnetic device, including a frame, a coil and a copper busbar winding installed in the frame, and a magnetic core installed on the frame. The copper busbar winding includes a plurality of copper busbar winding pieces spaced apart from the coil. At least one of the copper busbar winding pieces has heat dissipation feet at both ends of its connection point. The heat dissipation feet are connected to the housing on which the magnetic device is mounted by a thermally conductive material.

[0006] The frame includes: a first frame and a second frame installed in the middle of the first frame. The copper busbar winding and the wire disc are installed on the second frame. One side of the first frame is provided with a terminal for connecting the wire disc, and the other side is provided with a connector for the connecting end of the corresponding copper busbar winding piece.

[0007] Furthermore, the second frame is provided with multiple wire disc assembly slots spaced apart from top to bottom, and a copper busbar winding assembly slot for inserting copper busbar winding pieces is provided between each two adjacent wire disc assembly slots.

[0008] After the connecting end of the copper busbar winding sheet is bent downwards, it extends out parallel to the copper busbar winding sheet. The further away from the connecting seat, the greater the bending height of the copper busbar winding sheet, so that the connecting ends of multiple copper busbar winding sheets are stacked together, and the connecting end of the copper busbar winding sheet closest to the heat-conducting material on the housing extends out and fits against the heat dissipation foot of the heat-conducting material.

[0009] Preferably, the slot for inserting the copper busbar winding piece into the copper busbar winding assembly slot is located on one side of the first frame, and the outer edge of the copper busbar winding piece is provided with a protrusion protruding from the copper busbar winding assembly slot on the other side of the first frame.

[0010] The magnetic core includes: an I-type magnetic core installed at the bottom of the first frame, and an E-type magnetic core installed on the second frame and in contact with the I-type magnetic core. The central post of the E-type magnetic core passes through the first frame and the second frame, and the two side posts are close to the opposite sides of the second frame.

[0011] The present invention also proposes a voltage conversion device, including a housing and a PCB board, and further including the aforementioned magnetic device mounted on the housing. A set of screws passes through the PCB board and connects to the connection terminal, and another set of screws passes through the connection end of the PCB board and the copper busbar winding sheet and connects to the connection seat.

[0012] Furthermore, the housing is provided with multiple threaded connectors, and each threaded connector is provided with a pressure strip that is fixed to the top of the magnetic core by screws.

[0013] Preferably, the voltage conversion device is an on-board charger (OBC) or a voltage converter (DCDC).

[0014] Compared with existing technologies, this invention provides heat dissipation feet at the edges of the connecting ends of the copper busbar winding sheets. These feet can be connected to the housing where the magnetic components are mounted via a thermally conductive material. This allows the heat from the copper busbar winding, which is itself a heat source for the magnetic components, to be transferred away through thermal conduction. This direct heat dissipation method is highly efficient and far superior to existing heat conduction methods. Furthermore, the copper busbar winding is designed as a single-piece structure, which facilitates assembly and cost control. The stepped protrusions at the tail of the copper busbar winding facilitate subsequent adhesive application to fix the copper busbar winding onto the PCB board and frame. The individual coils are wound onto the frame, making operation convenient and facilitating coil assembly. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is an exploded view of the magnetic device in an embodiment of the present invention;

[0017] Figure 2 This is a schematic diagram of the structure in an embodiment of the present invention;

[0018] Figure 3 This is a front view of the second skeleton in an embodiment of the present invention;

[0019] Figure 4 This is a cross-sectional view of the second skeleton in an embodiment of the present invention;

[0020] Figure 5 This is a schematic diagram of the structure on the left side of the magnetic device in an embodiment of the present invention;

[0021] Figure 6 This is a schematic diagram of the structure on the right side of the magnetic device in an embodiment of the present invention;

[0022] Figure 7 This is a schematic diagram of the installation of the connection terminals in an embodiment of the present invention;

[0023] Figure 8 This is an exploded view from an embodiment of the present invention;

[0024] Figure 9 This is a schematic diagram of the structure of the magnetic device in an embodiment of the present invention;

[0025] Figure 10 This is a top view in an embodiment of the present invention. Detailed Implementation

[0026] To make the technical problems to be solved, the technical solutions, and the beneficial effects of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present invention and are not intended to limit the present invention.

[0027] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on or indirectly on that other component. When a component is referred to as being "connected to" another component, it can be directly connected to or indirectly connected to that other component.

[0028] In the description of this invention, it should be understood that the terms "center", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0029] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0030] The principles and structure of the present invention will be described in detail below with reference to the accompanying drawings and embodiments.

[0031] like Figure 1 , Figure 2 As shown, the present invention proposes a magnetic device, including: a frame 1, a coil 2, a copper busbar winding 3, and a magnetic core 4. The frame 1 is an insulating support for mounting the coil 2, the copper busbar winding 3, and the magnetic core 4. The coil 2 and the copper busbar winding 3 are mounted inside the frame 1, and the coil 2 and the copper busbar winding pieces 31 that make up the copper busbar winding 3 are spaced apart, that is, a copper busbar winding piece 31 is set between every two adjacent coil 2. The two ends of each copper busbar winding piece 31 are connection ends 32 parallel to the main body of the copper busbar winding piece 31, and all the copper busbar winding pieces 31 together form three stacked connection ends 32. The connection ends 32 are specifically connection pieces with round holes through which screws can pass, so that the stacked connection ends 32 can be connected and fixed by screws passing through. The edge of the connection end 32 of the copper busbar winding piece 31 closest to the bottom of the frame extends horizontally to form a heat dissipation foot 33. The heat dissipation foot 33 can be connected to the housing 5 on which the magnetic device is mounted through a heat-conducting material 53. The heat from the copper busbar winding 3 can be transferred out through thermal conduction to meet the heat dissipation requirements. The copper busbar winding itself is the heat source of the magnetic device, and the heat dissipation efficiency of directly discharging the heat source is high, which is far superior to the heat conduction method in the existing technology.

[0032] like Figure 2As shown, the skeleton 1 specifically includes a first skeleton 11 and a second skeleton 12. The middle part of the first skeleton 11 is a disc-shaped mounting platform. The middle part of the mounting platform is provided with a reserved hole through which the magnetic core 4 can pass. The second skeleton 12 is mounted on the mounting platform in the middle of the first skeleton 11. The mounting platform is provided with a bayonet. The bottom of the second skeleton 12 is provided with a buckle so that the first skeleton 11 and the second skeleton 12 are connected by a buckle, which facilitates installation and disassembly.

[0033] The right side of the first frame 11 is provided with two wiring terminals 111 for connecting wire discs 2, such as Figure 7 As shown, the terminal block 111 has bayonets 112 at both ends, and the first frame 11 has corresponding latches 113, so that the terminal block 111 can be latched and connected to the first frame 11, i.e., the output end. The terminal block 21 can be connected to the PCB board through a screw, and the first frame 11 has a threaded hole for the corresponding screw below the terminal block 21 for positioning.

[0034] The left side of the first frame 11 has two connector seats 114 with threaded holes. The connecting ends 32 of the copper busbar winding pieces 31 are stacked on the connector seats 114 and fixed to the connector seats 114 by screws passing through the through holes on the PCB board and the connecting ends 32, so that the copper busbar winding 3 is connected to the PCB board. All the copper busbar winding pieces 31 of the copper busbar winding 3 form three stacked connecting ends 32, with the middle stack of connecting ends 32 placed on the second connector seat on the housing. Figure 5 As shown, the left side of the first frame 11 is provided with limiting plastic 115 on both sides of the connection end where the three layers are stacked together, so that the connection end of the copper busbar winding sheet will not shift when stacked, reducing the difficulty of installation.

[0035] The second frame 12 is an axially hollow cylinder, with its hollow position directly opposite the pre-drilled hole on the first frame 11 for the magnetic core 4 to pass through. Figure 3 , Figure 4 As shown, the second frame 12 is provided with multiple wire disc assembly slots 121 spaced parallel from top to bottom. Between each pair of adjacent wire disc assembly slots 121, there is a copper busbar winding assembly slot 122 for inserting copper busbar winding pieces 31. After the second frame 12 is installed on the first frame 11, the slots of the copper busbar winding pieces 32 are used to insert the copper busbar winding pieces 32 with the slots facing to the left, so that the connecting ends 32 of the copper busbar winding pieces 32 can be stacked on the connecting seat 114 on the left side of the first frame. At the same time, the single-piece structure of the copper busbar winding pieces 32 is conducive to assembly and cost control, and the installation is simple and convenient.

[0036] like Figure 5As shown, the copper busbar winding piece 31 is bent into a ring shape to bring the connecting ends 32 of both ends together. The connecting ends 32 are bent downwards and extend parallel to the copper busbar winding piece 31. The bending height of the copper busbar winding piece 31 closer to the upper part of the second frame 12 is greater, causing the connecting ends of multiple copper busbar winding pieces 31 to overlap, and the connecting end of the bottom copper busbar winding piece 32 extends out to form a heat dissipation foot. Figure 6 As shown, the outer edge of the tail of the copper busbar winding piece 32 is provided with parallel protruding protrusions 34. The protrusions 34 protrude to the outside of the copper busbar winding assembly groove 122. The copper busbar winding assembly groove 122 is provided with a notch corresponding to the protrusions 34, located on the right side of the second frame 12, so that the copper busbar winding 3 forms multiple stepped protrusions 34 on the right side of the second frame 12, which can facilitate subsequent glue application to fix the copper busbar winding piece on the PCB board and the frame.

[0037] like Figure 4 As shown, the groove of the wire cake assembly groove 121 surrounds the side wall of the second frame 12, and the width between the top and bottom of the groove is equal to the thickness of the wire cake 2. Thus, the wire cake 2 can be directly wound on the second frame 12, reducing the difficulty of winding and improving the winding accuracy at the same time.

[0038] The magnetic core 4 includes two interlocking I-type magnetic cores 41 and E-type magnetic cores 42. The I-type magnetic core 41 is installed at the bottom of the first frame 11, and the E-type magnetic core 42 is fastened to the top of the second frame 12. The central column of the E-type magnetic core 42 passes through the center of the first frame 11 and the second frame 12 and is spliced ​​to the middle of the I-type magnetic core 41 located at the bottom of the first frame. The two side columns are close to the opposite sides of the second frame 12 and are spliced ​​to the two ends of the I-type magnetic core 41 located at the bottom of the first frame 11. At the same time, the top of the second frame 12 is provided with limiting ribs on both sides of the E-type magnetic core 42 to facilitate the positioning and installation of the E-type magnetic core 42 and to prevent the E-type magnetic core from moving laterally after installation.

[0039] like Figure 8 As shown, the present invention also includes a voltage conversion device, comprising a housing 5, a PCB board 6, and the aforementioned magnetic components. The housing 5 has mounting positions corresponding to the magnetic components, and limiting buckles are spaced around the mounting positions to restrict the lateral movement of the magnetic components on the housing 5. The housing 5 has a second connecting seat 51 with heat-conducting seats 52 on both sides, and heat-conducting material 53 is provided on the heat-conducting seats 52. Figure 2 As shown, after the magnetic device is installed, the heat dissipation foot 33 of the copper busbar winding 3 presses on the heat-conducting material 53, transferring heat to the housing.

[0040] The housing 5 is provided with two threaded connectors 54 with threaded holes for screw installation. Each threaded connector 54 is provided with a pressure strip 55 that is pressed against the top of the magnetic core 4 by screws. The pressure strip 55 can restrict the movement of the magnetic device in the longitudinal direction, thereby fixing the magnetic device to the housing 5.

[0041] like Figure 9 , Figure 10 As shown, the first frame is also provided with multiple vertically upward positioning posts 116, and the PCB board 6 has openings corresponding to the positioning posts 116 to facilitate positioning during PCB board installation.

[0042] In specific embodiments, the voltage conversion device can be an on-board charger (OBC) or a voltage converter (DCDC), or other devices with voltage conversion requirements, all of which are within the protection scope of this invention.

[0043] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A magnetic device, comprising a frame, a coil and copper busbar winding mounted within the frame, and a magnetic core mounted on the frame, characterized in that, The frame includes: a first frame having an installation platform and a second frame installed on the installation platform. One side of the installation platform is provided with a terminal block for connecting the wire disc, and the other side is provided with a connector for the connecting end of the copper busbar winding piece. The copper busbar winding and the wire disc are installed on the second frame. The copper busbar winding includes multiple copper busbar winding plates, and the coils and the copper busbar winding plates are spaced apart so that one copper busbar winding plate is placed between every two adjacent coils. The two ends of each copper busbar winding plate are connection ends parallel to the main body of the copper busbar winding plate. The connection ends of the copper busbar winding plates are bent downwards and extend parallel to the copper busbar winding plate. The further away from the connecting seat, the greater the bending height of the connection ends of the copper busbar winding plates, so that the connection ends of all the copper busbar winding plates are stacked together. At least one of the connection ends of the copper busbar winding plates is provided with heat dissipation feet, and the heat dissipation feet are connected to the housing on which the magnetic device is mounted through a thermally conductive material.

2. The magnetic device as described in claim 1, characterized in that, The second frame is provided with multiple wire disc assembly slots spaced apart from top to bottom, and a copper busbar winding assembly slot for inserting copper busbar winding pieces is provided between each two adjacent wire disc assembly slots.

3. The magnetic device as described in claim 1, characterized in that, The connecting end of the copper busbar winding piece closest to the thermally conductive material on the housing extends out to fit the heat dissipation foot of the thermally conductive material.

4. The magnetic device as described in claim 2, characterized in that, The slot for inserting the copper busbar winding piece into the copper busbar winding assembly slot is located on one side of the second frame, and the outer edge of the copper busbar winding piece is provided with a protrusion that protrudes from the copper busbar winding assembly slot on the other side of the second frame.

5. The magnetic device as described in claim 1, characterized in that, The magnetic core includes: an I-type magnetic core installed at the bottom of the first frame, and an E-type magnetic core installed on the second frame and in contact with the I-type magnetic core. The central column of the E-type magnetic core passes through the first frame and the second frame, and the two side columns are close to the opposite sides of the second frame.

6. A voltage conversion device, comprising a PCB board, characterized in that, It also includes the housing as described in any one of claims 1 to 5 and the magnetic device mounted on the housing.

7. The voltage conversion device as described in claim 6, characterized in that, One set of screws passes through the PCB board and connects to the connection terminal, while another set of screws passes through the connection end of the PCB board and the copper busbar winding sheet and connects to the connector.

8. The voltage conversion device as described in claim 6, characterized in that, The housing is provided with multiple threaded connectors, and each threaded connector is provided with a pressure bar that is fixed to the top of the magnetic core by screws.

9. The voltage conversion device as described in claim 6, characterized in that, The voltage conversion device is an on-board charger.

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