LLC Resonant Inductor Integrated Magnetic Circuit Structure of Flyback Transformer

Abstract

The present invention discloses an integrated resonant inductor magnetic circuit structure of an LLC charging transformer, which belongs to the technical field of magnetic core components and includes: a substrate, a magnetic core structure, an inner winding skeleton, an outer winding skeleton, an inner winding, an outer winding, and a plurality of leads; two of the magnetic core structures are respectively arranged oppositely on the substrate, and each of the magnetic core structures has a U-shaped part, an inner magnetic core, and an outer magnetic core; the inner magnetic core and the outer magnetic core are respectively arranged in the U-shaped part, and the outer magnetic core is sleeved outside the inner magnetic core. The inner winding skeleton is sleeved outside the inner magnetic core, and the outer winding skeleton is sleeved outside the outer magnetic core; the inner winding is wound and connected on the inner winding skeleton, and the outer winding is wound and connected on the outer winding skeleton. A plurality of the leads are uniformly distributed in the substrate. The integrated resonant inductor magnetic circuit structure of the LLC charging transformer of the present invention solves the technical problem of how to streamline the integrated structure of the LLC charging transformer and the inductor.

Description

Technical Field

[0001] The present invention relates to the technical field of magnetic core components for new energy vehicles, and particularly to an LLC charging transformer integrated resonant inductor magnetic circuit structure. Background Art

[0002] With the development of the new energy electric vehicle industry, the charging speed of the battery is one of the main factors restricting the development of new energy electric vehicles at present. In order to improve the charging speed of new energy electric vehicles, it can be achieved by configuring a DC charging pile with a higher power, and the power core unit of the charging pile is the charging module. Traditional charging modules generally adopt circuits such as an alternating current / direct current (AC / DC) rectification unit and a direct current / direct current (DC / DC) rectification unit. However, with the increasing requirements for current conversion efficiency and heat dissipation performance, the existing rectification circuits cannot meet the requirements. LLC is an abbreviation for Lr, Lm, and Cr, where Lr is the resonant inductor, Lm is the exciting inductor, and Cr is the resonant capacitor. The LLC resonant converter has the advantages of a high switching frequency, small turn-off loss, high conversion efficiency, low electromagnetic interference noise, and small switching stress. Therefore, this type of LLC resonant converter is currently widely used in charging piles.

[0003] Based on this, Chinese Patent CN106329940A discloses a full-bridge LLC resonant converter with a dual-transformer series-parallel structure, which includes a main circuit and a control module. The main circuit includes an input DC source, a full-bridge switch network, an LLC resonant network, a secondary rectification and filtering circuit, and a battery pack load connected in sequence. The control module includes an output voltage sampling circuit, an output current sampling circuit, a feedback adjustment circuit, a control chip, and a driving circuit. This type of full-bridge LLC resonant converter adopts a dual-converter series-parallel structure, where the primary windings of the two transformers are connected in series, and the currents flowing through the primary windings are the same, which can achieve automatic balancing of the secondary current, reduce the number of turns of the primary winding, and the secondary parallel connection can reduce the current stress of the secondary winding and rectifier diodes. The dual-transformer series-parallel structure is beneficial to reducing the volume of the magnetic core, dispersing the hot spots, and facilitating thermal management, and is suitable for medium and high-power new energy electric vehicle chargers.

[0004] However, there are still technical problems of complex structure and inconvenient layout in the transformers and resonant inductor magnetic circuits applied in the current circuit solutions. Specifically, the output power of the LLC resonant converter is limited and generally applicable to medium and low power products. To enable the charging module to obtain a higher output power, two or more LLC resonant converters can be connected in parallel or in series. However, if multiple LLC resonant converters are connected in parallel, current sharing is required for each LLC resonant converter. If multiple LLC resonant converters are connected in series, voltage equalization is required for each LLC resonant converter. To solve the problem that the currents are different when multiple LLC resonant converters are connected in parallel and the voltages are different when connected in series, resulting in different resonant parameters of the output electrical signals, it is generally necessary to add a current sharing or voltage equalization circuit to the circuit composed of multiple LLC resonant converters. This undoubtedly increases the cost of the entire circuit and makes the control strategy of the entire circuit relatively complex; it also makes the layout of the transformer and inductor relatively complex. Summary of the Invention

[0005] Based on this, in view of the technical problem of how to streamline the integrated structure of the LLC charging transformer and inductor, it is necessary to provide an LLC charging transformer integrated resonant inductor magnetic circuit structure.

[0006] An LLC charging transformer integrated resonant inductor magnetic circuit structure includes: a substrate, a magnetic core structure, an inner winding skeleton, an outer winding skeleton, an inner winding, an outer winding, and several leads; two of the magnetic core structures are oppositely arranged on the substrate respectively, and each magnetic core structure has a U-shaped part, an inner magnetic core, and an outer magnetic core; the inner magnetic core and the outer magnetic core are respectively arranged in the U-shaped part, and the outer magnetic core is sleeved outside the inner magnetic core. The inner winding skeleton is sleeved outside the inner magnetic core, and the outer winding skeleton is sleeved outside the outer magnetic core; the inner winding is wound and connected on the inner winding skeleton, and the outer winding is wound and connected on the outer winding skeleton. Several of the leads are evenly distributed in the substrate.

[0007] Further, the substrate has a main body, jacks, limit blocks, and guide rails.

[0008] Furthermore, several of the jacks are evenly arranged in the main body, and each jack is correspondingly and matingly connected to one of the leads.

[0009] Furthermore, a limit block is arranged at each corner of the main body; the two limit blocks on the same side limit and connect the two oppositely arranged magnetic core structures on the main body.

[0010] Furthermore, two guide rails are arranged in parallel on the main body, and the two guide rails are respectively matingly connected to the inner sides of the U-shaped parts.

[0011] Furthermore, the main body is provided with a plurality of main body openings, and the plurality of main body openings are evenly arranged in the main body.

[0012] Furthermore, the inner winding skeleton is provided with a plurality of inner skeleton openings, and the plurality of inner skeleton openings are evenly arranged in the inner winding skeleton.

[0013] Furthermore, the outer winding skeleton is provided with a plurality of outer skeleton openings, and the plurality of outer skeleton openings are evenly arranged in the outer winding skeleton.

[0014] Furthermore, the main body openings, the inner skeleton openings and the outer skeleton openings are arranged in the same vertical direction.

[0015] Furthermore, the outer winding skeleton is further provided with outer skeleton connecting parts, and the two outer skeleton connecting parts are respectively arranged at both ends of the outer winding skeleton, and each outer skeleton connecting part is arranged between the two limiting blocks.

[0016] In summary, the LLC charging transformer integrated resonant inductor magnetic circuit structure of the present invention is respectively provided with a substrate, a magnetic core structure, an inner winding skeleton, an outer winding skeleton, an inner winding, an outer winding and a plurality of leads; two magnetic core structures are respectively arranged opposite to each other on the substrate, and each magnetic core structure has a U-shaped part, an inner magnetic core and an outer magnetic core; the inner magnetic core and the outer magnetic core are respectively arranged in the U-shaped part, and the outer magnetic core is sleeved outside the inner magnetic core. The inner winding skeleton is sleeved outside the inner magnetic core, and the outer winding skeleton is sleeved outside the outer magnetic core; the inner winding is wound and connected on the inner winding skeleton, and the outer winding is wound and connected on the outer winding skeleton. The plurality of leads are evenly distributed in the substrate. The U-shaped part, the inner magnetic core and the outer magnetic core provided in one magnetic core structure are in contact and connected to each other. The inner winding skeleton is sleeved outside the two connected inner magnetic cores, and the inner winding skeleton is evenly wound with a wire with an insulating paint coating to form the inner winding. The outer magnetic core has a cylindrical structure, and the inner magnetic core, the inner winding skeleton and the inner winding are arranged inside it; and the outer winding skeleton is sleeved outside the outer magnetic core, and the outer winding skeleton is evenly wound with a wire with an insulating paint coating to form the outer winding; thus, a refined structural scheme of the transformer integrated resonant inductor magnetic circuit is constituted. Therefore, the LLC charging transformer integrated resonant inductor magnetic circuit structure of the present invention solves the technical problem of how to streamline the integrated structure of the LLC charging transformer and the inductor. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 is a structural schematic diagram of the LLC charging transformer integrated resonant inductor magnetic circuit structure of the present invention;

[0018] Figure 2 This is a schematic structural diagram of another direction of the integrated resonant inductor magnetic circuit structure of the LLC charging transformer of the present invention;

[0019] Figure 3 This is an exploded structural diagram of the integrated resonant inductor magnetic circuit structure of the LLC charging transformer of the present invention;

[0020] Figure 4 This is a schematic structural diagram of a partial structure of the integrated resonant inductor magnetic circuit structure of the LLC charging transformer of the present invention. Detailed implementation manners

[0021] In order to make the above objects, features, and advantages of the present invention more obvious and understandable, the following will describe the detailed implementation manners of the present invention with reference to the accompanying drawings. Many specific details are set forth in the following description in order to fully understand the present invention. However, the present invention can be implemented in many other ways different from those described herein, and those skilled in the art can make similar improvements without departing from the connotation of the present invention. Therefore, the present invention is not limited by the specific embodiments disclosed below.

[0022] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc. indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as limiting the present invention.

[0023] In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include at least one of such features. In the description of the present invention, "a plurality" means at least two, such as two, three, etc., unless otherwise specifically and clearly defined.

[0024] In the present invention, unless otherwise clearly specified or limited, the terms "mounted", "connected", "coupled", "fixed", etc. shall be construed in a broad sense. For example, it may be a fixed connection, a detachable connection, or integrated; it may be a mechanical connection or an electrical connection; it may be directly connected or indirectly connected through an intermediate medium, and it may be the internal communication between two components or the interaction relationship between two components, unless otherwise clearly limited. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0025] In the present invention, unless otherwise clearly specified or limited, the first feature being "on" or "under" the second feature may be that the first and second features are in direct contact, or the first and second features are indirectly in contact through an intermediate medium. Moreover, the first feature being "above", "over" and "on top of" the second feature may be that the first feature is directly above or obliquely above the second feature, or merely indicates that the first feature is at a higher horizontal level than the second feature. The first feature being "under", "beneath" and "underneath" the second feature may be that the first feature is directly below or obliquely below the second feature, or merely indicates that the first feature is at a lower horizontal level than the second feature.

[0026] It should be noted that when an element is referred to as "fixed to" or "disposed on" another element, it can be directly on the other element or there may also be an intermediate element. When an element is considered to be "connected" to another element, it can be directly connected to the other element or there may be an intermediate element at the same time. The terms "vertical", "horizontal", "up", "down", "left", "right" and similar expressions used herein are for illustrative purposes only and do not represent the only implementation.

[0027] Please refer to Figures 1 to 4 , the integrated resonant inductor magnetic circuit structure of the LLC charging transformer of the present invention includes: a substrate 1, a magnetic core structure 2, an inner winding skeleton 3, an outer winding skeleton 4, an inner winding 5, an outer winding 6, and a plurality of leads 7; two said magnetic core structures 2 are respectively oppositely arranged on the substrate 1, and each said magnetic core structure 2 has a U-shaped portion 201, an inner magnetic core 202, and an outer magnetic core 203; the inner magnetic core 202 and the outer magnetic core 203 are respectively arranged in the U-shaped portion 201, and the outer magnetic core 203 is sleeved outside the inner magnetic core 202. The inner winding skeleton 3 is sleeved outside the inner magnetic core 202, and the outer winding skeleton 4 is sleeved outside the outer magnetic core 203; the inner winding 5 is wound and connected on the inner winding skeleton 3, and the outer winding 6 is wound and connected on the outer winding skeleton 4. A plurality of said leads 7 are uniformly distributed in the substrate 1.

[0028] Specifically, in the solution of the LLC charging transformer integrated resonant inductor magnetic circuit structure of the present invention, various components are arranged on the substrate 1, and the two magnetic core structures 2 arranged on the substrate 1 are relatively abutted and connected. Thus, the U-shaped part 201, the inner magnetic core 202, and the outer magnetic core 203 provided in each magnetic core structure 2 are abutted and connected to each other. The inner winding skeleton 3 is sleeved outside the two connected inner magnetic cores 202, and a wire with an insulating paint coating is evenly wound on the inner winding skeleton 3 to form the inner winding 5. The outer magnetic core 203 has a cylindrical structure on the outside, and the inner magnetic core 202, the inner winding skeleton 3, and the inner winding 5 are arranged inside it; the outer winding skeleton 4 is sleeved outside the outer magnetic core 203, and a wire with an insulating paint coating is evenly wound on the outer winding skeleton 4 to form the outer winding 6. At the same time, a plurality of leads 7 are evenly arranged on the substrate 1 to communicate with an external circuit. Thus, the components arranged above can constitute a structural solution of a transformer integrated resonant inductor magnetic circuit applied to an LLC circuit. This structural solution has the advantages of being structurally compact and having a reduced volume, and can be conveniently arranged in a required circuit environment.

[0029] Further, the substrate 1 has a main body 101, jacks 102, limit blocks 103, and guide rails 104; a plurality of the jacks 102 are evenly arranged in the main body 101, and each jack 102 is correspondingly and matingly connected to one lead 7. A limit block 103 is arranged at each corner of the main body 101; the two limit blocks 103 on the same side limit and connect the two relatively arranged magnetic core structures 2 to the main body 101. Two guide rails 104 are arranged in parallel on the main body 101, and the two guide rails 104 are respectively matingly connected to the inner sides of the U-shaped parts 201. Specifically, the main body 1 provided on the substrate 1 is used to place the magnetic core structure 2, and a limit block 103 is arranged at each of the four corners of the main body 101. The two limit blocks 103 at the two corners on the same side of the main body 101 along the direction in which the two magnetic core structures 2 face each other respectively matingly connect the ends of the two U-shaped parts 201, thereby limiting and connecting the two magnetic core structures 2 to the main body 101. At the same time, the two guide rails 104 on the main body 101 are arranged inside the U-shaped parts 201, so as to accurately match and relatively connect the two magnetic core structures 2 to ensure that the two inner magnetic cores 202 and the two outer magnetic cores 203 can be aligned and connected.

[0030] Further, the main body 101 is provided with a plurality of main body openings 101a, and the plurality of main body openings 101a are uniformly arranged in the main body 101. The inner winding skeleton 3 is provided with a plurality of inner skeleton openings 301, and the plurality of inner skeleton openings 301 are uniformly arranged in the inner winding skeleton 3. The outer winding skeleton 4 is provided with a plurality of outer skeleton openings 401, and the plurality of outer skeleton openings 401 are uniformly arranged in the outer winding skeleton 4. More specifically, the main body openings 101a, the inner skeleton openings 301, and the outer skeleton openings 401 are arranged in the same vertical direction; thereby, the heat transfer and flow during the operation of the LLC full-bridge resonant inductor magnetic circuit structure of the present invention can be improved.

[0031] Further, the outer winding skeleton 4 is further provided with outer skeleton connection parts 402, and the two outer skeleton connection parts 402 are respectively arranged at both ends of the outer winding skeleton 4, and each outer skeleton connection part 402 is arranged between the two limit blocks 103.

[0032] In summary, the LLC full-bridge resonant inductor magnetic circuit structure of the present invention is respectively provided with a substrate 1, a magnetic core structure 2, an inner winding skeleton 3, an outer winding skeleton 4, an inner winding 5, an outer winding 6, and a plurality of leads 7; two magnetic core structures 2 are respectively arranged opposite to each other on the substrate 1, and each magnetic core structure 2 has a U-shaped part 201, an inner magnetic core 202, and an outer magnetic core 203; the inner magnetic core 202 and the outer magnetic core 203 are respectively arranged in the U-shaped part 201, and the outer magnetic core 203 is sleeved outside the inner magnetic core 202. The inner winding skeleton 3 is sleeved outside the inner magnetic core 202, and the outer winding skeleton 4 is sleeved outside the outer magnetic core 203; the inner winding 5 is wound and connected to the inner winding skeleton 3, and the outer winding 6 is wound and connected to the outer winding skeleton 4. The plurality of leads 7 are uniformly distributed in the substrate 1. The U-shaped part 201, the inner magnetic core 202, and the outer magnetic core 203 provided in one magnetic core structure 2 are in contact and connected to each other. The inner winding skeleton 3 is sleeved outside the two connected inner magnetic cores 2, and a wire with an insulating varnish coating is uniformly wound on the inner winding skeleton 3 to form the inner winding 5. The outer magnetic core 203 has a cylindrical structure, and the inner magnetic core 202, the inner winding skeleton 3, and the inner winding 5 are arranged inside it; and the outer winding skeleton 4 is sleeved outside the outer magnetic core 203, and a wire with an insulating varnish coating is uniformly wound on the outer winding skeleton 4 to form the outer winding 6; thereby, a concise structural scheme of the transformer integrated resonant inductor magnetic circuit is constituted. Therefore, the LLC full-bridge resonant inductor magnetic circuit structure of the present invention solves the technical problem of how to streamline the integrated structure of the LLC full-bridge transformer and the inductor.

[0033] The technical features of the above-described embodiments can be combined arbitrarily. For the sake of brevity of description, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, it should be considered as the scope described in this specification.

[0034] The above-described embodiments merely represent several implementation manners of the present invention. The description is relatively specific and detailed, but it should not be construed as a limitation on the scope of the invention patent. It should be noted that for those of ordinary skill in the art, without departing from the concept of the present invention, several modifications and improvements can still be made, and these all belong to the protection scope of the present invention. Therefore, the protection scope of the present invention patent shall be subject to the appended claims.

Claims

1. An LLC charging transformer integrated resonant inductor magnetic circuit structure, characterized in that It includes: a substrate (1), a magnetic core structure (2), an inner winding skeleton (3), an outer winding skeleton (4), an inner winding (5), an outer winding (6), and a plurality of leads (7); On the substrate (1), two of the magnetic core structures (2) are oppositely arranged. Each magnetic core structure (2) has a U-shaped part (201), an inner magnetic core (202), and an outer magnetic core (203). The inner magnetic core (202) and the outer magnetic core (203) are respectively arranged in the U-shaped part (201), and the outer magnetic core (203) is sleeved outside the inner magnetic core (202). The inner winding skeleton (3) is sleeved outside the inner magnetic core (202), and the outer winding skeleton (4) is sleeved outside the outer magnetic core (203). The inner winding (5) is wound and connected to the inner winding skeleton (3), and the outer winding (6) is wound and connected to the outer winding skeleton (4). A plurality of the leads (7) are evenly distributed in the substrate (1); The substrate (1) has a main body (101), jacks (102), limit blocks (103), and guide rails (104). A plurality of the jacks (102) are evenly arranged in the main body (101), and each jack (102) is correspondingly and matchingly connected to a lead (7). A limit block (103) is arranged at each corner of the main body (101). The two limit blocks (103) on the same side limit and connect the two oppositely arranged magnetic core structures (2) to the main body (101). Two guide rails (104) are arranged in parallel on the main body (101), and the two guide rails (104) are respectively matchingly connected to the inner sides of the U-shaped parts (201); The main body (101) is provided with a plurality of main body openings (101a), and the plurality of main body openings (101a) are evenly arranged in the main body (101). The inner winding skeleton (3) is provided with a plurality of inner skeleton openings (301), and the plurality of inner skeleton openings (301) are evenly arranged in the inner winding skeleton (3). The outer winding skeleton (4) is provided with a plurality of outer skeleton openings (401), and the plurality of outer skeleton openings (401) are evenly arranged in the outer winding skeleton (4). The main body openings (101a), the inner skeleton openings (301), and the outer skeleton openings (401) are arranged in the same vertical direction; The outer winding skeleton (4) is provided with outer skeleton connection parts (402). The two outer skeleton connection parts (402) are respectively arranged at both ends of the outer winding skeleton (4), and each outer skeleton connection part (402) is arranged between the two limit blocks (103).

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