An integrated transformer

Abstract

The present invention discloses an integrated transformer, comprising a base, a first coil module, and an inductor module; the first coil module comprises a first magnetic core, a primary winding, and a secondary winding, the primary winding being wound by a square stranded wire, the secondary winding being a copper foil winding, the secondary winding comprising two copper foil sheets, both of which are bent into a rectangular tube shape and arranged sequentially from the inside to the outside relative to the center of the first magnetic core, the copper foil sheets being provided with a first bending portion, the first bending portions of the two copper foil sheets being symmetrically arranged and forming a winding groove, the primary winding being arranged in the winding groove; in this way, through the design of the primary winding and the secondary winding, on the one hand, the square stranded wire is used to replace the insulating wire of the traditional primary winding, thereby reducing the volume of the winding, and on the other hand, the two copper foil sheets are bent into a rectangular tube shape to replace the use of the traditional skeleton, so as to achieve the purpose of meeting the requirements of small volume and high power, so that the product has good stability and improves the quality of the product.

Description

Technical Field

[0001] The present invention relates to the field of transformer technology, and in particular to an integrated transformer. Background Art

[0002] With the development of new energy vehicles, all-in-one electric drive systems have become a trend, with designs tending towards integration, compact size, and high power density. However, existing transformers still use conventional plastic frame structures, with design optimizations primarily focused on the magnetic core and wire material. This results in transformers being too large and having poor power density.

[0003] Therefore, it is necessary to study a new technical solution to solve the above problems. Summary of the Invention

[0004] In view of this, the present invention addresses the deficiencies in the prior art, and its main purpose is to provide an integrated transformer, which, through the design of the primary winding and the secondary winding, on the one hand utilizes square stranded wire to replace the insulated wire of the traditional primary winding, and on the other hand, two copper foils are bent into a rectangular tube to replace the use of the traditional skeleton, so as to achieve the purpose of small volume and high power.

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

[0006] An integrated transformer includes a base and a first coil module and an inductance module arranged on the base; wherein: the first coil module includes a first magnetic core, a primary winding and a secondary winding, the primary winding is formed by winding a square stranded wire, the secondary winding is a copper foil winding, and the secondary winding includes two copper foil sheets, both of which are bent into a rectangular tube shape and arranged in sequence from the inside to the outside relative to the center of the first magnetic core, and a first bending portion is provided on the copper foil sheets. The first bending portions of the two copper foil sheets are symmetrically arranged and form a winding groove for accommodating the primary winding, and the primary winding is arranged in the winding groove; the inductance module is arranged on one side of the first magnetic core.

[0007] As a preferred solution, the two copper foils are defined as a first copper foil and a second copper foil, respectively. The first copper foil is arranged on the inner side of the second copper foil, and the first bending portion of the first copper foil is bent upward from the upper right end of the first copper foil, and the first bending portion of the second copper foil is bent upward from the upper left end of the second copper foil.

[0008] As a preferred solution, a second bending portion is provided on the front side of the right end of the first copper foil, a third bending portion is provided on the rear side of the right end of the second copper foil, and a fourth bending portion is provided on the front and rear sides of the left end of the second copper foil. The right end of the primary winding is restricted by the first bending portion, the second bending portion of the first copper foil and the third bending portion of the second copper foil, and the left end of the primary winding is restricted by the first bending portion and the fourth bending portion of the second copper foil.

[0009] As a preferred solution, a first baffle and a second baffle are further included. The first baffle and the second baffle are respectively arranged at the left and right ends of the primary winding and are sandwiched between the primary winding and the corresponding bending portion.

[0010] As a preferred solution, the first baffle and the second baffle are both provided with at least three positioning parts, the three positioning parts of the first baffle correspond to the first bending part and the fourth bending part of the second copper foil, respectively, and the three positioning parts of the second baffle correspond to the first bending part, the second bending part and the third bending part of the first copper foil, respectively. The first bending part, the second bending part, the third bending part and the fourth bending part are all provided with positioning openings, and the positioning parts are adapted to be positioned at the positioning openings.

[0011] As a preferred solution, two of each of the first baffle and the second baffle are provided and arranged front to back, and the inner sides of the first baffle and the second baffle have positioning surfaces that match the outer peripheral surface of the copper foil.

[0012] As a preferred solution, a first extension portion is provided on the lower side of the right end of each of the first copper foil sheet and the second copper foil sheet, extending to the right. The first extension portion of the first copper foil sheet is provided on the upper side of the first extension portion of the second copper foil sheet, and a second extension portion is provided on the right end of the first extension portion, extending downward. A first clearance opening is provided at the lower end of the base corresponding to the second extension portion, and the lower end of the second extension portion is exposed from the first clearance opening; and the first extension portion of the first copper foil sheet and the first extension portion of the second copper foil sheet are located between the second bending portion and the third bending portion.

[0013] As a preferred solution, the lower ends of the second bending portion and the third bending portion are both extended to the right to form a third extension portion, the third extension portion is lower than the first extension portion, the right end of the third extension portion is extended downward to form a fourth extension portion, the lower end of the base is provided with a second clearance opening corresponding to the fourth extension portion, and the lower end of the fourth extension portion is exposed from the second clearance opening.

[0014] As a preferred embodiment, the present invention further comprises a second coil module, which is arranged on the left side of the first coil module. The second coil module comprises a second magnetic core, a skeleton and a coil winding. The coil winding is sleeved on the skeleton, and the skeleton is arranged at the center of the second magnetic core. The coil winding is wound with a square stranded wire. The primary winding and the coil winding are both connected to PIN pins. The primary winding and the coil winding both have lead wires, one end of the lead wire of the coil winding is connected to the primary winding, and the other end is connected to the PIN pin. The lower end of the base is provided with a third and a fourth clearance opening, and the PIN pins are exposed from the corresponding third and fourth clearance openings respectively.

[0015] The inductor module is arranged on the right side of the first coil module. The inductor module has two connection ends. The lower end of the base is provided with a fourth clearance opening corresponding to the inductor module. There are two fourth clearance openings, and the two connection ends are exposed from the two fourth clearance openings.

[0016] As a preferred solution, a plurality of lead slots are provided at the lower end of the base, the first PIN pin and the second PIN pin are respectively provided in the lead slots, and the lead wires of the coil winding and the lead wires of the primary winding are respectively extended into the corresponding lead slots and connected to the PIN pins;

[0017] A bottom plate is also provided, which is arranged at the lower end of the base, and the third and fourth make way openings are formed on the bottom plate.

[0018] Compared with the prior art, the present invention has obvious advantages and beneficial effects. Specifically, it can be seen from the above technical solution that it mainly adopts the design of the primary winding and the secondary winding. On the one hand, the insulating wire of the traditional primary winding is replaced by the square stranded wire, thereby reducing the volume of the winding and meeting the voltage resistance and safety distance requirements of the transformer. On the other hand, two copper foils are bent into a rectangular tube to replace the use of the traditional skeleton, so as to achieve the purpose of meeting the requirements of small volume and high power, so that the product has good stability. At the same time, the leakage inductance of the transformer is reduced, solving the problem of excessively high leakage inductance of the transformer, improving the quality of the product, and effectively reducing the material cost and production cost.

[0019] Secondly, the provision of the second, third, and fourth bending portions facilitates the assembly and positioning of the primary winding on the secondary winding. At the same time, the provision of the first and second baffles ensures the stability of the primary winding. Furthermore, the provision of the positioning portion and the positioning opening facilitates the assembly and positioning of the first and second baffles on the copper foil.

[0020] In addition, the setting of the second coil module further improves the power density of the product to meet the use requirements of new energy products. At the same time, the setting of the lead groove is conducive to the layout design of the lead wires and PIN pins.

[0021] In order to more clearly illustrate the structural features and effects of the present invention, the present invention is described in detail below with reference to the accompanying drawings and specific embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a three-dimensional schematic diagram of an embodiment of the present invention;

[0023] Figure 2 is a cross-sectional view of an embodiment of the present invention;

[0024] Figure 3 yes Figure 2 A partial enlarged schematic diagram of the structure shown;

[0025] Figure 4 is an exploded view of an embodiment of the present invention;

[0026] Figure 5 2 is a schematic diagram of a base according to an embodiment of the present invention.

[0027] Description of the accompanying drawings:

[0028] 10. Base 101, first yielding opening

[0029] 102, second yield gate 103, fifth yield gate

[0030] 11. Bottom plate 111, third yield opening

[0031] 112, side panel 113, buckle hole

[0032] 12. Lead groove 13. Buckle part

[0033] 20. First coil module 201, positioning part

[0034] 21. First magnetic core 22. Primary winding

[0035] 23. Secondary winding 231. First copper foil

[0036] 232, second copper foil 233, first bending portion

[0037] 234, second bending portion 235, third bending portion

[0038] 236, fourth bending portion 237, fifth bending portion

[0039] 238, sixth bending portion 239, positioning opening

[0040] 24. First baffle 25. Second baffle

[0041] 261, first extension portion 262, second extension portion

[0042] 263, third extension portion 264, fourth extension portion

[0043] 27, PIN 30, inductor module

[0044] 31, connection terminal 40, second coil module

[0045] 41. Second magnetic core 42. Skeleton

[0046] 43. Coil winding. DETAILED DESCRIPTION

[0047] Please refer to Figures 1 to 5 As shown, it shows the specific structure of an embodiment of the present invention.

[0048] An integrated transformer includes a base 10 and a first coil module 20 and an inductor module 30 arranged on the base 10; wherein: the first coil module 20 includes a first magnetic core 21, a primary winding 22 and a secondary winding 23, the primary winding 22 is wound by a square stranded wire, the secondary winding 23 is a copper foil winding, and the secondary winding 23 includes two copper foil sheets, both of which are bent into a rectangular tube shape and are arranged in sequence from the inside to the outside relative to the center of the first magnetic core 21. A first bending portion 233 is provided on the upper surface, and the first bending portions 233 of the two copper foils are symmetrically arranged and form a winding groove for accommodating the primary winding, and the primary winding 22 is arranged in the winding groove; the inductor module 30 is arranged on one side of the first magnetic core 21; in this way, through the design of the primary winding and the secondary winding, on the one hand, the square stranded wire is used to replace the insulating wire of the traditional primary winding, and on the other hand, the two copper foils are bent into a rectangular tube to replace the use of the traditional skeleton, so as to achieve the purpose of small volume and high power.

[0049] In this embodiment, the two copper foils are defined as a first copper foil 231 and a second copper foil 232, respectively. The first copper foil 231 is arranged on the inner side of the second copper foil 232, and the first bending portion 233 of the first copper foil 231 is bent upward from the upper right end of the first copper foil 231. The first bending portion 233 of the second copper foil 232 is bent upward from the upper left end of the second copper foil 232.

[0050] In addition, a second bending portion 234 is provided on the front side of the right end of the first copper foil 231, a third bending portion 235 is provided on the rear side of the right end of the second copper foil 232, and a fourth bending portion 236 is provided on the front and rear sides of the left end of the second copper foil 232. The right end of the primary winding 22 is restricted by the first bending portion 233, the second bending portion 234 of the first copper foil 231 and the third bending portion 235 of the second copper foil 232, and the left end of the primary winding 22 is restricted by the first bending portion 233 and the fourth bending portion 236 of the second copper foil 232. Here, the upper end of the first bending portion 233 of the first copper foil 231 is bent to the right to be provided with a fifth bending portion 237, and the upper end of the first bending portion 233 of the second copper foil 232 is bent to the left to be provided with a sixth bending portion 238, which increases the heat dissipation area and improves the heat dissipation effect of the product.

[0051] It also includes a first baffle 24 and a second baffle 25, which are respectively arranged at the left and right ends of the primary winding 22, and are clamped between the primary winding 22 and the corresponding bending portion; here, the first baffle 24 and the second baffle 25 are both provided with at least three positioning portions 201, and the three positioning portions 201 of the first baffle 24 are respectively provided corresponding to the first bending portion 233 and the fourth bending portion 236 of the second copper foil 232, and the three positioning portions 301 of the second baffle 25 are respectively provided corresponding to the first bending portion 233, the second bending portion 234 and the third bending portion 235 of the first copper foil 231 and the second copper foil 232, and the first bending portion 233, the second bending portion 234, the third bending portion 235 and the fourth bending portion 236 are all provided with positioning openings 239, and the positioning portion 201 is adapted to be positioned in the positioning openings 239.

[0052] Preferably, two of each of the first baffle 24 and the second baffle 25 are provided and arranged front to back, and the inner sides of each of the first baffle 24 and the second baffle 25 have positioning surfaces that match the outer peripheral surface of the copper foil.

[0053] In addition, a first extension portion 261 is provided on the lower side of the right end of each of the first copper foil sheet 231 and the second copper foil sheet 232, extending rightward. The first extension portion 261 of the first copper foil sheet 231 is provided on the upper side of the first extension portion 261 of the second copper foil sheet 232. A second extension portion 262 is provided on the right end of the first extension portion 261, extending downward. A first clearance opening 101 is provided at the lower end of the base 10 corresponding to the second extension portion 262, and the lower end of the second extension portion 262 is exposed from the first clearance opening 101. Moreover, the first extension portion 261 of the first copper foil sheet 231 and the first extension portion 263 of the second copper foil sheet 232 are located between the second bending portion 234 and the third bending portion 235.

[0054] Here, the lower ends of the second bending portion 234 and the third bending portion 235 are both extended to the right to form a third extension portion 263, and the third extension portion 263 is lower than the first extension portion 261. The right end of the third extension portion 263 is extended downward to form a fourth extension portion 264. The lower end of the base 10 is provided with a second clearance opening 102 corresponding to the fourth extension portion 264, and the lower end of the fourth extension portion 264 is exposed from the second clearance opening 102.

[0055] The second coil module 40 is further included. The second coil module 40 is arranged on the left side of the first coil module 20. The second coil module 40 includes a second magnetic core 41, a skeleton 42 and a coil winding 43. The coil winding 43 is sleeved on the skeleton 42. The skeleton 42 is arranged at the center of the second magnetic core 41. The coil winding 43 is wound by a square stranded wire. The primary winding 22 and the coil winding 43 are both connected to the PIN pin 27. The primary winding 22 and the coil winding 43 both have lead wires. One end of the lead wire of the coil winding 43 is connected to the primary winding 22, and the other end is connected to the PIN pin 27. The lower end of the base 10 is provided with a third clearance opening 111, and the PIN pins 27 are respectively exposed from the corresponding third clearance opening 111.

[0056] The inductor module 30 is disposed on the right side of the first coil module 20 . The inductor module 30 has two connection terminals 31 . A fourth clearance opening 103 is provided at the lower end of the base 10 corresponding to the inductor module 30 . There are two fourth clearance openings 103 , and the two connection terminals 31 are exposed from the two fourth clearance openings 103 .

[0057] Furthermore, a plurality of lead slots 12 are provided at the lower end of the base 10, and the PIN pins are provided in the lead slots 12. The lead wires of the coil winding 43 and the lead wires of the primary winding 22 are respectively extended into the corresponding lead slots 12 and connected to the PIN pins 27.

[0058] A bottom plate 11 is also provided, which is arranged at the lower end of the base 10, and the third clearance opening 111 is formed on the bottom plate 11; here, the bottom plate 11 is assembled on the base 10 in a snap-fit ​​manner, and a snap-fit ​​portion 13 is provided on the base 10. The bottom plate 11 has a side plate 112 extending upward, and a snap-fit ​​hole 113 is provided on the side plate 112. The snap-fit ​​hole 113 is adapted to be positioned on the snap-fit ​​portion 13 to realize the assembly connection between the bottom plate 11 and the base 10, thereby closing the lead groove.

[0059] The key points of the present invention are that, through the design of the primary and secondary windings, on the one hand, the use of square stranded wire to replace the insulation wire of the traditional primary winding reduces the volume of the winding and meets the voltage resistance and safety distance requirements of the transformer. On the other hand, two copper foils are bent into a rectangular tube to replace the use of the traditional bobbin, so as to achieve the purpose of meeting the requirements of small volume and high power, making the product have good stability. At the same time, the leakage inductance of the transformer is reduced, solving the problem of excessively high leakage inductance of the transformer, improving the quality of the product, and effectively reducing the material cost and production cost.

[0060] Secondly, the provision of the second, third, and fourth bending portions facilitates the assembly and positioning of the primary winding on the secondary winding. At the same time, the provision of the first and second baffles ensures the stability of the primary winding. Furthermore, the provision of the positioning portion and the positioning opening facilitates the assembly and positioning of the first and second baffles on the copper foil.

[0061] In addition, the setting of the second coil module further improves the power density of the product to meet the use requirements of new energy products. At the same time, the setting of the lead groove is conducive to the layout design of the lead wires and PIN pins.

[0062] The above description is merely a preferred embodiment of the present invention and does not limit the technical scope of the present invention. Therefore, any minor modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. An integrated transformer, characterized in that: It includes a base and a first coil module and an inductance module arranged on the base; wherein: the first coil module includes a first magnetic core, a primary winding and a secondary winding, the primary winding is formed by winding a square stranded wire, the secondary winding is a copper foil winding, and the secondary winding includes two copper foil sheets, the two copper foil sheets are bent into a rectangular tube and are arranged in sequence from the inside to the outside relative to the center of the first magnetic core, a first bending portion is provided on the copper foil sheet, the first bending portions of the two copper foil sheets are symmetrically arranged and form a winding groove for accommodating the primary winding, and the primary winding is arranged in the winding groove; the inductance module is arranged on one side of the first magnetic core; the two copper foil sheets are respectively defined as a first copper foil sheet and a second copper foil sheet, the first copper foil sheet is arranged on the inner side of the second copper foil sheet, the first bending portion of the first copper foil sheet is bent upward from the upper right end of the first copper foil sheet, and the first bending portion of the second copper foil sheet is bent upward from the upper left end of the second copper foil sheet.

2. The integrated transformer according to claim 1, characterized in that: A second bending portion is provided on the front side of the right end of the first copper foil sheet, a third bending portion is provided on the rear side of the right end of the second copper foil sheet, and a fourth bending portion is provided on the front and rear sides of the left end of the second copper foil sheet. The right end of the primary winding is restricted by the first bending portion, the second bending portion and the third bending portion of the first copper foil sheet and the left end of the primary winding is restricted by the first bending portion and the fourth bending portion of the second copper foil sheet.

3. The integrated transformer according to claim 2, characterized in that: The invention also includes a first baffle and a second baffle, which are respectively arranged at the left and right ends of the primary winding and sandwiched between the primary winding and the corresponding bending portion.

4. The integrated transformer according to claim 3, characterized in that: The first baffle and the second baffle are both provided with at least three positioning parts, the three positioning parts of the first baffle correspond to the first bending part and the fourth bending part of the second copper foil, respectively, and the three positioning parts of the second baffle correspond to the first bending part, the second bending part and the third bending part of the first copper foil, respectively. The first bending part, the second bending part, the third bending part and the fourth bending part are all provided with positioning openings, and the positioning parts are adapted to be positioned at the positioning openings.

5. The integrated transformer according to claim 4, characterized in that: Two of the first baffles and the second baffles are provided and arranged front to back. The inner sides of the first baffles and the second baffles each have a positioning surface that matches the outer peripheral surface of the copper foil.

6. The integrated transformer according to claim 2, characterized in that: A first extension portion is provided on the lower side of the right end of each of the first copper foil sheet and the second copper foil sheet, extending rightward. The first extension portion of the first copper foil sheet is provided on the upper side of the first extension portion of the second copper foil sheet, and a second extension portion is provided on the right end of the first extension portion, extending downward. A first clearance opening is provided at the lower end of the base corresponding to the second extension portion, and the lower end of the second extension portion is exposed from the first clearance opening; and the first extension portion of the first copper foil sheet and the first extension portion of the second copper foil sheet are located between the second bending portion and the third bending portion.

7. The integrated transformer according to claim 6, characterized in that: The lower ends of the second and third bending portions are both extended to the right to form a third extension portion, the third extension portion is lower than the first extension portion, the right end of the third extension portion is extended downward to form a fourth extension portion, the lower end of the base is provided with a second clearance opening corresponding to the fourth extension portion, and the lower end of the fourth extension portion is exposed from the second clearance opening.

8. The integrated transformer according to claim 1, characterized in that: The second coil module is further included, and the second coil module is arranged on the left side of the first coil module. The second coil module includes a second magnetic core, a skeleton and a coil winding. The coil winding is sleeved on the skeleton, and the skeleton is arranged at the center of the second magnetic core. The primary winding and the coil winding are both connected to PIN pins. The primary winding and the coil winding both have lead wires, one end of the lead wire of the coil winding is connected to the primary winding, and the other end is connected to the PIN pin. The lower end of the base is provided with a third and a fourth clearance opening, and the PIN pins are exposed from the corresponding third and fourth clearance openings respectively. The inductor module is arranged on the right side of the first coil module. The inductor module has two connection ends. The lower end of the base is provided with a fourth clearance opening corresponding to the inductor module. There are two fourth clearance openings, and the two connection ends are exposed from the two fourth clearance openings.

9. The integrated transformer according to claim 8, characterized in that: The lower end of the base is provided with a plurality of lead grooves, the PIN pins are provided in the lead grooves, the lead wires of the coil winding and the lead wires of the primary winding are respectively extended into the corresponding lead grooves and connected to the PIN pins; A bottom plate is also provided, which is arranged at the lower end of the base, and the third and fourth make way openings are formed on the bottom plate.

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