LLC magnetic integrated high-frequency transformer

Abstract

The application relates to the technical field of high-frequency transformers, in particular to an LLC magnetic integrated high-frequency transformer which comprises an inner core and a shell. A framework is arranged in the inner core, a primary winding and a secondary winding are wound on the framework, a through hole is arranged in the framework, a middle column magnetic core is connected through the through hole, E-shaped magnetic cores are arranged on the two sides of the framework, the E-shaped magnetic cores are matched with the middle column magnetic core to form a double circuit, the shell is used for fixing the assembled framework, the shell is divided into an upper shell body and a lower shell body, fixing blocks are arranged on the inner sides of the upper and lower shell bodies, the fixing blocks are used for fixing the E-shaped magnetic cores, insulating shells and fixing baffles are arranged on the upper and lower shell bodies, and the insulating shells and the fixing baffles are used for fixing the framework. The application is simple in assembly, convenient in production and high in production efficiency, thereby reducing production cost and energy loss and being beneficial to improving the overall efficiency of the power supply.

Description

Technical Field

[0001] This invention relates to the field of high-frequency transformer technology, and specifically to an LLC magnetically integrated high-frequency transformer. Background Technology

[0002] High-frequency transformers are power transformers that operate at frequencies exceeding intermediate frequencies (10kHz). They are mainly used in high-frequency switching power supplies as high-frequency switching power supply transformers, and are also used in high-frequency inverter power supplies and high-frequency inverter welding machines as high-frequency inverter power supply transformers.

[0003] High-frequency transformers are the most important component of switching power supplies. There are many topologies in switching power supplies, and LLC circuits are one of them. An LLC circuit consists of two inductors and one capacitor. It is a resonant circuit that achieves a constant output voltage by controlling the switching frequency (frequency regulation). Through soft-switching technology, it achieves zero-voltage turn-on of the two main MOS switches on the primary side and zero-current turn-off of the rectifier diodes on the secondary side, which can reduce the switching losses of the power supply and improve the efficiency and power density of the power converter.

[0004] Existing LLC high-frequency transformers are widely favored due to their small size and high efficiency. However, because they have internal coil windings, LLC high-frequency transformers are mostly assembled manually. The assembly of existing LLC high-frequency transformers is relatively difficult and complex, resulting in a high defect rate and rework rate, which reduces production efficiency and increases production costs, causing inconvenience to enterprises. Summary of the Invention

[0005] The purpose of this invention is to provide an LLC magnetically integrated high-frequency transformer that is simple to assemble, stable, and beneficial to improving production efficiency and reducing production costs.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: an LLC magnetic integrated high-frequency transformer, comprising a shell and an inner core, wherein a frame is provided in the inner core, a support column is provided in the frame, and a first partition, a second partition, a third partition and a fourth partition are sequentially provided on the support column, a primary winding is wound between the first partition and the second partition, and a secondary winding is wound between the third partition and the fourth partition, a through hole is provided in the support column, a central core is inserted into the through hole, E-shaped cores are provided on both sides of the frame, and a shell is provided outside the inner core, the shell comprising an upper shell and a lower shell, the upper shell and the lower shell being fixedly connected, and the upper shell and the lower shell clamping and fixing the inner core.

[0007] Furthermore, the E-shaped magnetic core is provided with side wall connections of two side protrusions and a central protrusion. The two side protrusions are in contact with the two ends of the central core, and an air gap is formed between the central protrusion and the central core.

[0008] Furthermore, the upper housing has fixing holes at its four corners, and the lower housing has threaded holes at positions corresponding to the fixing holes, through which fastening screws are connected.

[0009] Furthermore, an insulating shell is provided at a corresponding position between the first partition and the second partition of the outer shell. There is one insulating shell on the upper shell and one on the lower shell, and heat dissipation holes are provided on the insulating shell.

[0010] Furthermore, the outer shell is provided with a fixing baffle at the position corresponding to the fourth partition, with one fixing baffle on each of the upper and lower shells.

[0011] Furthermore, the outer shell has fixing blocks at the four inner corners, with four fixing blocks on each of the upper and lower shells and corresponding to each other. The distance between each group of fixing blocks is consistent with the thickness of the E-shaped magnetic core.

[0012] The beneficial effects of this invention are: simple assembly, easy production and improved production efficiency, thereby reducing production costs, while reducing energy consumption and improving the overall efficiency of the power supply. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0014] Figure 2 This is a schematic diagram of the outer shell structure of the present invention;

[0015] Figure 3 This is a schematic diagram of the core structure of the present invention;

[0016] Figure 4 This is a schematic diagram of the skeleton structure of the present invention;

[0017] Figure 5 This is a schematic diagram of the magnetic core structure of the present invention.

[0018] The names corresponding to each mark in the diagram:

[0019] 1. Outer shell; 11. Upper shell; 111. Fixing hole; 112. Insulating shell; 113. Heat dissipation hole; 114. Fastening screw; 115. Fixing baffle; 12. Lower shell; 121. Threaded hole; 122. Fixing block; 2. Inner core; 21. Frame; 211. First partition; 212. Second partition; 213. Support; 214. Third partition; 215. Fourth partition; 216. Through hole; 22. Central core; 23. E-shaped core; 231. Side protrusions; 232. Central protrusion; 233. Air gap; 24. Winding; 241. Primary winding; 242. Secondary winding. Detailed Implementation

[0020] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention are within the scope of protection of the present invention.

[0021] Embodiments of the present invention:

[0022] like Figure 1-3 As shown, the present invention includes an inner core 2, a frame 21 is provided in the inner core 2, E-shaped magnetic cores 23 are provided on both sides of the frame 21, and an outer shell 1 is provided outside the inner core 2. The outer shell 1 includes an upper shell 11 and a lower shell 12. Fixing blocks 122 are provided at the four corners of the inner side of the upper shell 11 and the lower shell 12. Fixing holes 111 are provided at the four corners of the upper shell 11, and threaded holes 121 are provided at the four corners of the lower shell 12. Fastening screws 114 are connected through the fixing holes 111 and the threaded holes 121. The upper shell 11 and the lower shell 12 are connected and fixed by the fastening screws 114.

[0023] like Figure 2-5 As shown, a support column 213 is provided in the frame 21. A first partition 211, a second partition 212, a third partition 214, and a fourth partition 215 are arranged sequentially on the support column 213. A primary winding 241 is wound between the first partition 211 and the second partition 212, and a secondary winding 242 is wound between the third partition 214 and the fourth partition 215. A through hole 216 is provided in the frame 21, penetrating the support column 213. A central core magnetic core 22 is inserted into the through hole 216. E-shaped magnetic cores 23 are provided on both sides of the magnetic core 22. The E-shaped magnetic core 23 includes two side protrusions 231 and a middle protrusion 232. The two side protrusions 231 are in contact with the two ends of the central core 22. An air gap 233 is formed between the middle protrusion 232 and the central core 22. The upper housing 11 and the lower housing 12 are provided with an insulating shell 112 at the primary winding, and heat dissipation holes 113 are provided on the insulating shell 112. At the same time, a fixing baffle 115 is provided at the fourth partition 215.

[0024] This invention is simple to assemble. All components, such as the skeleton 21, the central magnetic core 22, and the E-shaped magnetic core 23, can be manufactured as standard parts, and corresponding standard-sized outer shells 1 can also be produced. Therefore, during assembly, only the primary winding 241 and the secondary winding 242 need to be wound, and the central magnetic core 22 needs to be inserted. Then, the skeleton 21 is placed in the lower shell 12. At this time, the first partition 211 and the second partition 212 are supported by the insulating shell 112, and the fourth partition 215 is supported by the fixed baffle 115, thus achieving support for the skeleton 21. The support is then placed on both sides of the frame, and the E-shaped magnetic cores 23 are supported by the fixing blocks 122 at the four corners. After installation, the upper shell 11 is covered. The fixing blocks 122 at the four corners of the inner side of the upper shell 11, together with the fixing blocks 122 at the four corners of the inner side of the lower shell, press and fix the E-shaped magnetic cores 23. The insulating shells 112 and fixing baffles 115 on the upper shell 11 and the lower shell 12 fix the frame 21, ensuring the stability of the entire high-frequency transformer after installation. At this time, the fastening screws 114 can be connected.

[0025] The principle of this invention is as follows: the central core 22 faces the two E-shaped cores 23, and together with the primary winding 241 and the secondary winding 242, a dual-circuit circuit is formed, and two inductances are generated. At the same time, two leakage inductances are formed on both sides of the central core 22, which greatly increases the large leakage inductance required by the LLC circuit, thereby solving the LLC circuit's requirement for PFC inductors.

[0026] This invention is simple to assemble, greatly reducing production costs and improving production efficiency. At the same time, by magnetically integrating the PFC inductor and the main transformer together, the number of turns in the primary winding 241 and the secondary winding 242 can be reduced, thereby reducing costs. In addition, this magnetic integration method reduces losses and improves efficiency by eliminating one PFC inductor, which can greatly save energy. The insulating shell 112 not only serves a fixing function, but also solves the withstand voltage problem between the primary winding 241 and the secondary winding 242, allowing it to meet the UL certification standard of 3750V.

Claims

1. An LLC magnetically integrated high-frequency transformer, characterized in that: The device includes an outer shell (1) and an inner core (2). The inner core (2) is provided with a frame (21). The frame (21) is provided with a support column (213). The support column (213) is provided with a first partition (211), a second partition (212), a third partition (214), and a fourth partition (215) in sequence. A primary winding (241) is wound between the first partition (211) and the second partition (212). A winding is wound between the third partition (214) and the fourth partition (215). The inner core (2) is wound with a secondary winding (242), and a through hole (216) is provided in the support column (213). A central column magnetic core (22) is inserted into the through hole (216). E-shaped magnetic cores (23) are provided on both sides of the frame (21). An outer shell (1) is provided outside the inner core (2). The outer shell (1) includes an upper shell (11) and a lower shell (12). The upper shell (11) and the lower shell (12) are fixedly connected. The upper shell (11) and the lower shell (12) clamp and fix the inner core (2). The outer shell (1) is provided with an insulating shell (112) at the corresponding position between the first partition (211) and the second partition (212). There is one insulating shell (112) on the upper shell (11) and one on the lower shell (12). The insulating shell (112) is provided with heat dissipation holes (113). The outer shell (1) is provided with a fixed baffle (115) at the position corresponding to the fourth partition (215), and there is one fixed baffle (115) on the upper shell (11) and one on the lower shell (12); The outer shell (1) has four fixing blocks (122) at the four inner corners. There are four fixing blocks (122) on the upper shell (11) and four on the lower shell (12), and they correspond to each other. The distance between each group of fixing blocks (122) is consistent with the thickness of the E-shaped magnetic core (23).

2. The LLC magnetically integrated high-frequency transformer according to claim 1, characterized in that: The E-shaped magnetic core (23) is provided with side wall connections of two side protrusions (231) and a central protrusion (232). The two side protrusions (231) are in contact with the two ends of the central core (22), and an air gap (233) is formed between the central protrusion (232) and the central core (22).

3. The LLC magnetically integrated high-frequency transformer according to claim 1, characterized in that: The upper housing (11) is provided with fixing holes (111) at the four corners, and the lower housing (12) is provided with threaded holes (121) at the corresponding positions of the fixing holes (111). Fastening screws (114) are connected through the fixing holes (111) and the threaded holes (121).

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