A high power density transformer

Abstract

The present application relates to a high-power-density transformer, including a bottom plate; a magnetic core, arranged on the bottom plate, with two of them spaced apart; a side column, arranged on the bottom plate, with multiple side columns located between the two magnetic cores, the two ends of the multiple side columns being the farthest apart are respectively connected to the two magnetic cores, and a winding area is formed between the side columns and the magnetic cores; a magnetic sheet, arranged in the winding area, with multiple of them spaced apart along the direction of the connection between the two magnetic cores, the multiple magnetic sheets are divided into two groups, and a buffer is arranged between the two end faces of the two groups of magnetic sheets that are closest to each other; an air gap plate, located in each group of magnetic sheets, with one air gap plate located between two adjacent magnetic sheets or between a magnetic sheet and a magnetic core; a coil, wound on the magnetic core and multiple magnetic sheets. The present application has the effect of making the transformer smaller and adapting the transformer to an installation environment with greater vibration.

Description

Technical Field

[0001] The present application relates to the field of magnetic components, and in particular to a high power density transformer. Background Art

[0002] Magnetic components commonly used in power electronic products, such as transformers and inductors, usually require an air gap to be formed on the magnetic core to adjust the inductance of the product. Specifically, the air gap sheets and magnetic sheets are stacked alternately.

[0003] In the related art, such as publication number CN217640924U, the magnetic components include a main magnetic core, a wire wrap frame, a coil, a segmented air gap frame, a magnetic sheet and a base, the coil is arranged on the outer periphery of the wire wrap frame; there are multiple magnetic sheets, which are respectively inserted between two adjacent air gap sheets in the segmented air gap frame, and the other end of each magnetic sheet is bonded to the main magnetic core, the wire wrap frame is cylindrical, and the segmented air gap frame and the magnetic sheet are located inside the wire wrap frame; the main magnetic core is fixedly connected to the base.

[0004] Regarding the above-mentioned related technologies, there is a problem that since the air gap sheet is a part of the air gap frame, and the air gap frame is made of a hard material, it will not only make the volume of the transformer larger, but also make the transformer difficult to adapt to the installation environment with large vibration. Summary of the invention

[0005] In order to make the transformer smaller and adapt the transformer to an installation environment with greater vibration, the present application provides a transformer with a high power density.

[0006] A high power density transformer provided in this application adopts the following technical solution:

[0007] A high power density transformer, comprising:

[0008] Base plate;

[0009] The magnetic cores are arranged on the bottom plate, and two of them are spaced apart from each other;

[0010] Side columns are arranged on the bottom plate, a plurality of the side columns are located between the two magnetic cores, two ends of the side columns that are farthest from each other are respectively connected to the two magnetic cores, and a winding area is formed between the side columns and the magnetic cores;

[0011] A magnetic sheet is arranged in the winding area, and a plurality of magnetic sheets are spaced apart along the connecting direction between the two magnetic cores, and the plurality of magnetic sheets are divided into two groups, and a buffer pad is arranged between the two end surfaces of the two groups of magnetic sheets that are closest to each other;

[0012] An air gap plate is located in each group of the magnetic sheets, and one of the air gap plates is located between two adjacent magnetic sheets or between the magnetic sheet and the magnetic core;

[0013] The coil is wound around the magnetic core and the plurality of magnetic sheets.

[0014] By adopting the above technical solution, firstly, the air gap plate is directly connected to the magnetic sheet and the magnetic core, and there is no air gap frame, so the volume of the transformer can be smaller; secondly, the setting of the buffer pad allows the transformer to adapt to an installation environment with large vibration, and the buffer pad is only set between the two groups of magnetic sheets, which will not affect the basic performance of the transformer.

[0015] Preferably, the plurality of magnetic sheets are evenly divided into two groups.

[0016] By adopting the above technical solution, a group of magnetic sheets, a magnetic core and multiple side columns are first assembled into a semi-finished product, and the two semi-finished products are then assembled into a transformer. During the assembly process, the buffer pad can be directly placed between the two semi-finished products, thereby making the assembly of the transformer more convenient.

[0017] Preferably, the magnetic sheet and the magnetic core are provided with limit stops on the end faces cooperating with the air gap plate, and a plurality of the limit stops are evenly distributed in a circle around the center of the magnetic sheet, and a limit groove for accommodating the air gap plate is formed on the inner side of the plurality of limit stops, and the depth of the limit groove is less than half the thickness of the air gap plate.

[0018] By adopting the above technical scheme, the limiting groove formed by the limiting block can allow the air gap plate to be aligned with the center of the magnetic sheet, and one air gap plate will cooperate with two adjacent magnetic sheets, and will also cooperate with the magnetic sheet and the magnetic core. At the same time, the depth of the limiting groove is less than half the thickness of the air gap plate, and there will be no direct contact between the magnetic sheets and the magnetic sheets, and between the magnetic sheets and the magnetic core. Therefore, while maintaining the air gap, the magnetic sheets can be aligned with each other and with the magnetic core, thereby reducing the assembly tolerance between the magnetic sheets and between the magnetic sheets and the magnetic core, thereby improving the comprehensive performance of the transformer. In addition, the intervals between the multiple limiting blocks also facilitate the operation of inserting the air gap plate into the limiting groove.

[0019] Preferably, a temperature equalizing plate is provided on a side of the bottom plate away from the magnetic core and the side column.

[0020] By adopting the above technical solution, since the transformer is small in size, the power density is high. Therefore, the setting of the temperature equalization plate can use smaller components to more efficiently dissipate the heat of the transformer, thereby efficiently dissipating the heat of the transformer without increasing the size of the transformer too much, thereby improving the working stability of the transformer.

[0021] Preferably, the magnetic core and the side columns are provided with positioning grooves at two corners close to the base plate, the positioning grooves at each corner are connected to each other, and the cross-section of the positioning groove is a sector with a central angle of 90°; the base plate is provided with a positioning rod, and the positioning rod is passed through the positioning groove.

[0022] By adopting the above technical solution, with the help of the cooperation between the positioning rod and the positioning slot, the two magnetic cores can be directly aligned on the base plate to improve the assembly accuracy between the two magnetic cores, thereby also improving the assembly efficiency. In addition, the positioning slot is only located at the corners of the magnetic core and the side column, and will not significantly affect the magnetic field generated by the magnetic core and the side column.

[0023] Preferably, a positioning mounting seat is provided on the bottom plate, the positioning rod corresponding to a corner cooperates with a positioning mounting seat, the positioning mounting seat is slidably arranged, and the sliding direction is perpendicular to the connecting direction of the two magnetic cores. The positioning mounting seat is connected with a clamping spring, and the clamping spring is used to apply an elastic force to bring the two positioning mounting seats closer to each other.

[0024] By adopting the above technical solution, compared with the method of fixing the positioning rod, with this design method, before the magnetic core and the side column are placed on the base plate, the distance between the two positioning mounting seats can be closer under the action of the clamping spring, and after the magnetic core and the side column are subsequently placed on the floor, the distance between the two positioning mounting seats can become farther to adapt to the distance between the positioning slots in the two corners. At the same time, the clamping spring will apply an elastic force to the positioning mounting seats to move them closer to each other, so the shape tolerance of the magnetic core and the side column can be ignored to make the relative position between the positioning rods adapt to the positioning slots between the two corners, and the clamping spring can be used to make the magnetic core and the side column more stably set on the base plate.

[0025] Preferably, the positioning rod is in the form of a heat pipe structure, and one positioning mounting seat is equipped with two positioning rods. The positioning rod is slidably arranged on the positioning mounting seat, and the movement direction of the positioning rod is parallel to the direction of the connection line between the two magnetic cores. A driven tube and an active screw are arranged between the two positioning rods, and one driven tube is connected to one positioning rod. The driven tube has the same outer diameter as the positioning rod, and both ends of the active screw are respectively threadedly arranged on the inner sides of the two driven tubes, and the threads at both ends of the active screw have opposite rotation directions.

[0026] By adopting the above technical solution, after the two magnetic cores are fixed, the active screw can be rotated to move the two driven tubes away from each other, so that the two positioning rods are gradually moved away from each other until one end of the positioning rod is in the positioning groove and the other end is outside the range of the magnetic core and the side column. Therefore, the heat of the transformer can be diffused to a farther place with the help of the positioning rod, thereby improving the heat dissipation efficiency of the transformer.

[0027] Preferably, the active screw sleeve is provided with a transmission pulley, and the base plate is provided with a transmission belt, a part of the transmission belt passes through the base plate, and the other part passes through the base plate and abuts against the part of the transmission pulley close to the positioning groove, the passing position is located on the side away from each other between the positioning rods corresponding to different corners, and the passing part is wrapped around the side of the base plate away from the magnetic core.

[0028] By adopting the above technical solution, with the help of the cooperation between the transmission belt and the transmission pulley, the movement of the positioning rods on the two positioning mounting seats can be controlled by one transmission belt, so the operation can be more convenient. At the same time, the transmission belt is also exposed on the side of the bottom plate away from the magnetic core, and the transmission belt provides enough area for the operator to pull, thereby making the operation of the transformer during the installation process more convenient.

[0029] Preferably, a toothed pulley transmission is formed between the transmission belt and the transmission pulley.

[0030] By adopting the above technical solution, the transmission synchronization between the transmission belt and the transmission pulley can be improved, and then the movement synchronization of the positioning rod between the two positioning mounting seats can be improved.

[0031] In summary, the present application includes at least one of the following beneficial technical effects:

[0032] First, the air gap plate is directly connected to the magnetic sheet and the magnetic core, and there is no air gap frame, so the volume of the transformer can be smaller; second, the setting of the buffer pad allows the transformer to adapt to the installation environment with large vibration, and the buffer pad is only set between the two sets of magnetic sheets, which will not affect the basic performance of the transformer;

[0033] After the two magnetic cores are fixed, the active screw can be rotated to move the two driven tubes away from each other, so that the two positioning rods are gradually moved away from each other until one end of the positioning rod is in the positioning groove and the other end is outside the range of the magnetic core and the side column. Therefore, the positioning rod can be used to diffuse the heat of the transformer to a farther place, thereby improving the heat dissipation efficiency of the transformer. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 It is a schematic diagram of the structure of the transformer in the embodiment of the present application.

[0035] Figure 2 It is a schematic diagram made to illustrate the coordination structure between the air gap plate, the magnetic sheet and the magnetic core in the embodiment of the present application.

[0036] Figure 3 It is a schematic diagram of the structure of a transformer equipped with a heat dissipation device in an embodiment of the present application.

[0037] Figure 4 It is a schematic diagram for illustrating how the positioning rods are close to or away from each other in the embodiment of the present application.

[0038] Explanation of the reference numerals in the accompanying drawings: 1. Base plate; 11. Temperature equalizing plate; 2. Magnetic core; 3. Side column; 31. Winding area; 4. Magnetic sheet; 41. Buffer pad; 5. Air gap plate; 51. Limit block; 52. Limit groove; 6. Coil; 7. Positioning through groove; 71. Positioning rod; 8. Positioning mounting seat; 81. Clamping spring; 9. Driven tube; 91. Active screw; 92. Transmission pulley; 93. Transmission belt. DETAILED DESCRIPTION

[0039] The following is combined with Figure 1-4 This application is described in further detail.

[0040] The embodiment of the present application discloses a transformer with high power density.

[0041] Reference Figure 1 and Figure 2 The high power density transformer comprises a bottom plate 1, a magnetic core 2, a side column 3, a magnetic sheet 4, an air gap plate 5 and a coil 6, wherein the bottom plate 1 is roughly in the shape of a rectangular thin plate; the magnetic core 2 is fixedly arranged on the bottom plate 1, and two magnetic cores 2 are spaced apart along the length direction of the bottom plate 1; the side column 3 is fixedly arranged on the bottom plate 1, and there are four side columns 3 in total, and the four side columns 3 are located between two magnetic cores 2, and the two ends of the four side columns 3 that are farthest away are respectively connected to the two magnetic cores 2, and the two side columns 3 are connected to one magnetic core 2, and the side columns 3 and the magnetic core 2 are surrounded to form a winding area 31; the magnetic sheet 4 is arranged in the winding area 31, and a plurality of magnetic sheets 4 are spaced apart along the connecting line direction between the two magnetic cores 2, and the plurality of magnetic sheets 4 are divided into two groups, and a buffer pad 41 is arranged between the two end faces of the two groups of magnetic sheets 4 that are closest to each other; the air gap plate 5 is located in each group of magnetic sheets 4, and one air gap plate 5 is located between two adjacent magnetic sheets 4 or between the magnetic sheet 4 and the magnetic core 2; the coil 6 is wound around the magnetic core 2 and the plurality of magnetic sheets 4.

[0042] Reference Figure 1 and Figure 2 The transformer has the following advantages: first, the air gap plate 5 is directly connected to the magnetic sheet 4 and the magnetic core 2, and there is no air gap frame, so the volume of the transformer can be smaller; second, the setting of the buffer pad 41 allows the transformer to adapt to an installation environment with large vibration, and the buffer pad 41 is only set between the two groups of magnetic sheets 4, and will not affect the basic performance of the transformer.

[0043] In addition, in this embodiment, a magnetic core 2, two side columns 3 and a group of magnetic sheets 4 are manufactured as a semi-finished product, and in order to facilitate the buffer pad 41 to be set between the two groups of magnetic sheets 4, the number of the two groups of magnetic sheets 4 is the same, so that the assembly of the transformer can be more convenient.

[0044] Reference Figure 1 and Figure 2 In order to improve the alignment accuracy between the magnetic sheets 4 and between the magnetic sheets 4 and the magnetic core 2, the following settings are correspondingly arranged: the magnetic sheets 4 and the magnetic core 2 are provided with limit stops 51 on the end faces that cooperate with the air gap plate 5, and a plurality of limit stops 51 are evenly spaced around the center of the magnetic sheet 4 in a circumferential manner, and a plurality of limit stops 51 are formed on the inner sides of the plurality of limit stops 51 to accommodate the air gap plate 5. The depth of the limit groove 52 is less than half the thickness of the air gap plate 5, so that the air gap plate 5 can be accurately located at the center of the magnetic sheet 4, and one air gap plate 5 will cooperate with two adjacent magnetic sheets 4, and will also Cooperating with the magnetic sheet 4 and the magnetic core 2, the depth of the limit groove 52 is less than half the thickness of the air gap plate 5, and there will be no direct contact between the magnetic sheets 4 and the magnetic sheets 4, and between the magnetic sheets 4 and the magnetic core 2. Therefore, while maintaining the air gap, the magnetic sheets 4 can be aligned with each other, and the magnetic sheets 4 can be aligned with the magnetic core 2, thereby reducing the assembly tolerance between the magnetic sheets 4 and between the magnetic sheets 4 and the magnetic core 2, thereby improving the comprehensive performance of the transformer. In addition, the intervals between the multiple limit blocks 51 also facilitate the operation of inserting the air gap plate 5 into the limit groove 52.

[0045] Reference Figure 3 and Figure 4 In order to improve the installation accuracy between the two magnetic cores 2, the following settings are correspondingly arranged: the magnetic core 2 and the side column 3 are provided with positioning grooves 7 at two corners close to the bottom plate 1, and the positioning grooves 7 at each corner are connected. The cross-section of the positioning groove 7 is a sector with a central angle of 90°. At the same time, the bottom plate 1 is provided with a positioning rod 71, and the positioning rod 71 is penetrated in the positioning groove 7. Therefore, the magnetic core 2 can be directly aligned on the bottom plate 1 with the help of the cooperation between the positioning rod 71 and the positioning groove 7, thereby improving the assembly efficiency. In addition, the positioning groove 7 is only located at the corners of the magnetic core 2 and the side column 3, so it will not affect the magnetic field generated by the magnetic core 2 and the side column 3.

[0046] Reference Figure 3 and Figure 4 Since the positioning and alignment between the magnetic cores 2 is achieved by the cooperation between the positioning slots 7 and the positioning rods 71, the shape accuracy of the magnetic cores 2 and the side columns 3 will affect the distance between the positioning rods 71 ​​of the two corners. Therefore, in order to reduce the difficulty of alignment between the magnetic cores 2, the following settings are correspondingly arranged: a positioning mounting seat 8 is arranged on the bottom plate 1, and a positioning rod 71 corresponding to a corner cooperates with a positioning mounting seat 8. The positioning mounting seat 8 is slidably arranged, and the sliding direction is perpendicular to the connection direction of the two magnetic cores 2. The positioning mounting seat 8 is connected to a clamping spring 81, and the other end of the clamping spring 81 is the bottom plate 1. The clamping spring 81 will exert an elastic force to bring the two positioning mounting seats 8 closer to each other.

[0047] Reference Figure 3 and Figure 4 Before the magnetic core 2 and the side column 3 are placed on the base plate 1, the distance between the two positioning mounting seats 8 can be closer under the action of the clamping spring 81. After the magnetic core 2 and the side column 3 are subsequently placed on the floor, the distance between the two positioning mounting seats 8 can become farther to adapt to the distance between the positioning slots 7 in the two corners. At the same time, the clamping spring 81 will apply an elastic force to the positioning mounting seats 8 to move them closer to each other. Therefore, the shape tolerance of the magnetic core 2 and the side column 3 can be ignored to allow the relative position of the positioning rod 71 to adapt to the positioning slot 7 between the two corners, and the clamping spring 81 can be used to make the magnetic core 2 and the side column 3 more stably set on the base plate 1.

[0048] Reference Figure 3 and Figure 4 In order to improve the heat dissipation efficiency of the transformer without significantly increasing the volume of the transformer, the following settings are correspondingly provided: the positioning rod 71 is a heat pipe structure, a positioning mounting seat 8 is equipped with two positioning rods 71, the positioning rod 71 is slidably arranged on the positioning mounting seat 8, the movement direction of the positioning rod 71 is parallel to the connection direction between the two magnetic cores 2, a driven tube 9 and an active screw 91 are arranged between the two positioning rods 71, a driven tube 9 is connected to a positioning rod 71, the driven tube 9 has the same outer diameter as the positioning rod 71, and the two ends of the active screw 91 are respectively threadedly penetrated on the inner side of the two driven tubes 9, and the threads at the two ends of the active screw 91 are rotated in opposite directions. After the assembly between the two magnetic cores 2 is completed, the active screw 91 can be rotated to make the two driven tubes 9 move away from each other, so that the two positioning rods 71 ​​gradually move away from each other, until one end of the positioning rod 71 is in the positioning slot 7, and the other end is outside the range of the magnetic core 2 and the side column 3. Therefore, the heat of the transformer can be diffused to a farther place with the help of the positioning rod 71, thereby improving the heat dissipation efficiency of the transformer.

[0049] Reference Figure 3 and Figure 4 In order to improve the convenience of operating the active screw rod 91, the following settings are correspondingly arranged: the active screw rod 91 is sleeved with a transmission pulley 92, and the bottom plate 1 is provided with a transmission belt 93. A part of the transmission belt 93 passes through the bottom plate 1, and the other part passes through the bottom plate 1 and abuts against the part of the transmission pulley 92 close to the positioning groove 7. The passing position is located on the side away from each other between the positioning rods 71 ​​corresponding to different corners, and the passing part is wrapped around the side of the bottom plate 1 away from the magnetic core 2, so that a transmission belt 93 can be used to control the movement of the positioning rods 71 ​​on the two positioning mounting seats 8. At the same time, the transmission belt 93 is also exposed on the side of the bottom plate 1 away from the magnetic core 2, and the transmission belt 93 provides enough area for the operator to pull, so that the operation of the transformer during the installation process is more convenient. In addition, considering the transmission synchronization, the transmission belt 93 and the transmission pulley 92 are toothed pulley transmission.

[0050] Reference Figure 3 and Figure 4 In this embodiment, a temperature equalizing plate 11 is further provided on the side of the bottom plate 1 away from the magnetic core 2 to improve the heat dissipation efficiency of the transformer, but the volume of the transformer will not be significantly increased. At the same time, the transfer belt 93 is also wound around the side of the temperature equalizing plate 11 away from the magnetic core 2.

[0051] The implementation principle of a high power density transformer in an embodiment of the present application is as follows: first, the air gap plate 5 is directly connected to the magnetic sheet 4 and the magnetic core 2, and there is no air gap frame, so the volume of the transformer can be smaller; second, the setting of the buffer pad 41 allows the transformer to adapt to an installation environment with greater vibration, and the buffer pad 41 is only set between the two groups of magnetic sheets 4, and will not affect the basic performance of the transformer.

[0052] The above are all preferred embodiments of the present application, and the protection scope of the present application is not limited thereto. Therefore, any equivalent changes made according to the structure, shape, and principle of the present application should be included in the protection scope of the present application.

Claims

1. A high power density transformer, characterized in that: include: Bottom plate (1); The magnetic cores (2) are arranged on the bottom plate (1), and two of them are spaced apart from each other; Side columns (3) are arranged on the bottom plate (1), a plurality of the side columns (3) are located between the two magnetic cores (2), two ends of the side columns (3) that are farthest apart are respectively connected to the two magnetic cores (2), and a winding area (31) is formed between the side columns (3) and the magnetic cores (2); A magnetic sheet (4) is arranged in the winding area (31), and a plurality of the magnetic sheets (4) are spaced apart along the direction of the connection between the two magnetic cores (2); the plurality of magnetic sheets (4) are divided into two groups, and a buffer pad (41) is arranged between the two end surfaces of the two groups of magnetic sheets (4) that are closest to each other; An air gap plate (5) is located in each group of the magnetic sheets (4), and one of the air gap plates (5) is located between two adjacent magnetic sheets (4) or between the magnetic sheet (4) and the magnetic core (2); A coil (6) wound around the magnetic core (2) and the plurality of magnetic sheets (4); The plurality of magnetic sheets (4) are evenly divided into two groups; The magnetic core (2) and the side column (3) are provided with positioning slots (7) at two corners close to the bottom plate (1); the positioning slots (7) at each corner are connected to each other, and the cross section of the positioning slots (7) is fan-shaped with a central angle of 90°; the bottom plate (1) is provided with a positioning rod (71), and the positioning rod (71) is inserted into the positioning slot (7); A positioning mounting seat (8) is arranged on the bottom plate (1); a positioning rod (71) corresponding to a corner cooperates with a positioning mounting seat (8); the positioning mounting seat (8) is slidably arranged, and the sliding direction is perpendicular to the connection direction of the two magnetic cores (2); the positioning mounting seat (8) is connected to a clamping spring (81), and the clamping spring (81) is used to apply an elastic force to bring the two positioning mounting seats (8) closer to each other.

2. The high power density transformer according to claim 1, characterized in that: The magnetic sheet (4) and the magnetic core (2) are provided with limit stops (51) on the end faces matching the air gap plate (5); a plurality of the limit stops (51) are evenly spaced and distributed in a circumferential manner around the center of the magnetic sheet (4); a limit groove (52) for accommodating the air gap plate (5) is formed on the inner side of the plurality of limit stops (51); the depth of the limit groove (52) is less than half the thickness of the air gap plate (5).

3. The high power density transformer according to claim 1, characterized in that: A temperature equalizing plate (11) is provided on one side of the bottom plate (1) away from the magnetic core (2) and the side column (3).

4. The high power density transformer according to claim 1, characterized in that: The positioning rod (71) is in the form of a heat pipe structure. One positioning mounting seat (8) is matched with two positioning rods (71). The positioning rod (71) is slidably arranged on the positioning mounting seat (8). The movement direction of the positioning rod (71) is parallel to the direction of the connection line between the two magnetic cores (2). A driven tube (9) and an active screw (91) are arranged between the two positioning rods (71). One driven tube (9) is connected to one positioning rod (71). The driven tube (9) and the positioning rod (71) have the same outer diameter. The two ends of the active screw (91) are respectively threadedly arranged on the inner sides of the two driven tubes (9). The threads at the two ends of the active screw (91) have opposite rotation directions.

5. The high power density transformer according to claim 4, characterized in that: The active screw rod (91) is sleeved with a transmission pulley (92), and the base plate (1) is provided with a transmission belt (93). A portion of the transmission belt (93) passes through the base plate (1), and another portion passes through the base plate (1) and abuts against a portion of the transmission pulley (92) close to the positioning slot (7). The passing position is located on a side of the positioning rods (71) corresponding to different corners that are away from each other, and the passing portion is wound around a side of the base plate (1) that is away from the magnetic core (2).

6. The high power density transformer according to claim 5, characterized in that: The transmission belt (93) and the transmission pulley (92) are toothed pulley transmission.

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