Main harmonic integrated transformer and vehicle-mounted charger

Abstract

The invention provides a main harmonic integrated transformer and a vehicle-mounted charger, and relates to the technical field of transformers. The main harmonic integrated transformer comprises a base, a magnetic core, a primary winding, a secondary winding and a magnetic block, the magnetic core is fixed to the first side of the base, the magnetic block is installed on the second side of the base in a replaceable mode and corresponds to the primary winding in position, and the first side is opposite to the second side; the magnetic core is provided with a primary side magnetic column and a secondary side magnetic column which are arranged in a separated mode, the primary side winding is arranged on the primary side magnetic column in a sleeved mode, the secondary side winding is arranged on the secondary side magnetic column in a sleeved mode, and the cross section area of the primary side magnetic column is different from that of the secondary side magnetic column. A resonance coil and a resonance magnetic core do not need to serve as a resonance inductor, magnetic leakage is absorbed by means of a magnetic block and a primary winding, and therefore the resonance inductor and a main magnetic circuit are integrated, the structure is simplified, and electromagnetic interference can be reduced. The secondary winding and the primary winding are arranged on different magnetic columns respectively, mutual interference is small, the sectional areas of the primary magnetic column and the secondary magnetic column are different, cost is reduced, and the size of the magnetic core is fully utilized.

Description

Technical Field

[0001] The present invention relates to the technical field of transformers, and in particular to a main-harmonic integrated transformer and a vehicle-mounted charger. Background Art

[0002] In existing on-board chargers, the resonant inductor and the main transformer are independent of each other and are used in the circuit as two discrete components, resulting in the presence of multiple power magnetic devices in the entire product. The total loss is large, which is not conducive to improving the efficiency of the product. In addition, the multiple power magnetic devices generate serious heat as a whole, have a large total volume, and have a high heat dissipation cost, which is not conducive to the high power density and miniaturization development of the product. Summary of the invention

[0003] The present invention provides a main-resonant integrated transformer and an on-board charger, which are used to solve the defects in the prior art that the resonant inductor and the main transformer are separately arranged, there are many power magnetic components, and the heat dissipation and miniaturization of the product are affected.

[0004] The present invention provides a main-harmonic integrated transformer, comprising: a base, a magnetic core, a primary winding, a secondary winding and a magnetic block, wherein the magnetic core is fixed to a first side of the base, and the magnetic block can be replaceably installed on a second side of the base and corresponds to the position of the primary winding, and the first side is opposite to the second side; the magnetic core has a primary magnetic column and a secondary magnetic column that are separately arranged, the primary winding is sleeved on the primary magnetic column, and the secondary winding is sleeved on the secondary magnetic column, wherein the cross-sectional area of ​​the primary magnetic column is different from that of the secondary magnetic column.

[0005] According to a main-harmonic integrated transformer provided by the present invention, the primary winding includes a primary frame and a primary coil, the primary frame includes a sleeve and a rib, the ribs are provided on opposite sides of the sleeve, the sleeve is sleeved on the primary magnetic column, the primary coil is wound on the sleeve and limited by the ribs, the base has a first through hole and a second through hole, one end of the primary coil is passed through the first through hole, and the other end is passed through the second through hole.

[0006] According to a main-resonant integrated transformer provided by the present invention, the number of winding layers of the primary coil on the primary frame does not exceed 3 layers.

[0007] According to a main-harmonic integrated transformer provided by the present invention, the secondary winding includes a secondary frame and a secondary copper busbar, the secondary frame is U-shaped, the secondary copper busbar is sleeved on the secondary frame, the base is provided with a socket, the open end of the secondary copper busbar is inserted into the socket and extends to the second side of the base.

[0008] According to a main-resonant integrated transformer provided by the present invention, the secondary copper busbar has an intermediate tap.

[0009] According to a main-harmonic integrated transformer provided by the present invention, there is a gap between the two secondary copper bars and they are fixed by welding through connecting terminals.

[0010] According to a main-harmonic integrated transformer provided by the present invention, the magnetic core has a first guide groove and a second guide groove, the first guide groove is arranged corresponding to the primary winding, and the second guide groove is arranged corresponding to the secondary winding.

[0011] According to a main-harmonic integrated transformer provided by the present invention, a receiving groove is provided on the second side of the base, and clamping holes are respectively provided on opposite sides of the bottom of the receiving groove, and protrusions are respectively provided on opposite sides of the magnetic block, and the two protrusions are clamped in the two clamping holes one by one.

[0012] According to a main-resonant integrated transformer provided by the present invention, a vertical plate is provided on the base, and the vertical plate is located between the secondary winding and the primary winding.

[0013] The present invention also provides a vehicle-mounted charger, which comprises the main-harmonic integrated transformer as described above.

[0014] The main-resonant integrated transformer provided by the present invention does not require a resonant coil and a resonant magnetic core as a resonant inductor, and uses a magnetic block and a primary winding to absorb leakage magnetic flux, so that the resonant inductor is integrated with the main magnetic circuit, which simplifies the structure and reduces electromagnetic interference; the secondary winding and the primary winding are arranged on different magnetic columns, and there is little interference between them, and the cross-sectional areas of the primary magnetic column and the secondary magnetic column are different, which reduces the cost and makes full use of the volume of the magnetic core. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] In order to more clearly illustrate the technical solutions in the present invention or the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0016] Figure 1 It is a three-dimensional diagram of the main-harmonic integrated transformer provided by the present invention.

[0017] Figure 2 It is a schematic diagram of the relative positions of the magnetic core and the magnetic block provided by the present invention.

[0018] Figure 3 yes Figure 1 The exploded view of the main-resonant integrated transformer is shown.

[0019] Figure 4 It is a schematic diagram of the cooperation between the base and the magnetic block provided by the present invention.

[0020] Figure 5It is a circuit principle diagram of the main-resonant integrated transformer provided by the present invention when the secondary winding has an intermediate tap.

[0021] Figure 6 It is a circuit principle diagram of the main-resonant integrated transformer provided by the present invention when the secondary winding has no intermediate tap.

[0022] Figure 7 It is a schematic diagram of the magnetic ring structure formed by the primary magnetic column and the secondary magnetic column provided by the present invention.

[0023] Figure 8 yes Figure 7 Schematic diagram of the magnetic flux of the magnetic ring shown.

[0024] Fig. 9 It is a schematic diagram of the magnetic ring structure formed by the primary magnetic column and the magnetic block provided by the present invention.

[0025] Fig.10 yes Fig. 9 Schematic diagram of the magnetic flux of the magnetic ring shown.

[0026] Reference numerals: 10. Base; 11. First through hole; 12. Second through hole; 13. Plug; 14. Accommodating slot; 15. Clamp hole; 16. Vertical plate; 20. Magnetic core; 21. Primary magnetic column; 22. Secondary magnetic column; 23. First guide groove; 24. Secondary guide groove; 30. Primary winding; 31. Primary frame; 32. Primary coil; 40. Secondary winding; 41. Secondary frame; 42. Secondary copper busbar; 50. Magnetic block; 51. Bump. DETAILED DESCRIPTION

[0027] In order to make the purpose, technical solution and advantages of the present invention clearer, the technical solution of the present invention will be clearly and completely described below in conjunction with the drawings of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0028] The features of the terms "first" and "second" in the specification and claims of the present invention may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, "plurality" means two or more. In addition, "and / or" in the specification and claims means at least one of the connected objects, and the character " / " generally means that the objects connected before and after are in an "or" relationship.

[0029] In the description of the present invention, it is to be understood that the terms “center”, “longitudinal”, “lateral”, “length”, “width”, “thickness”, “up”, “down”, “front”, “back”, “left”, “right”, “vertical”, “horizontal”, “top”, “bottom”, “inside”, “outside”, “clockwise”, “counterclockwise”, “axial”, “radial”, “circumferential”, etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0030] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0031] Combine the following Figure 1-Figure 10 The main-resonant integrated transformer of the present invention is described.

[0032] The present invention provides a main-harmonic integrated transformer, such as Figures 1 to 3 As shown, it includes a base 10, a magnetic core 20, a primary winding 30, a secondary winding 40 and a magnetic block 50. The magnetic core 20 is fixed to the first side of the base 10, and the magnetic block 50 can be replaced and installed on the second side of the base 10 and corresponds to the position of the primary winding 30, and the first side is opposite to the second side. Figure 2 and Figure 3 As shown, the magnetic core 20 has a primary magnetic column 21 and a secondary magnetic column 22 which are separated, the primary winding 30 is sleeved on the primary magnetic column 21, and the secondary winding 40 is sleeved on the secondary magnetic column 22. The cross-sectional areas of the primary magnetic column 21 and the secondary magnetic column 22 are different.

[0033] The primary magnetic column 21 and the secondary magnetic column 22 form a Figure 7 The magnetic flux of the magnetic ring shown is Figure 8 The primary winding 30 and the primary magnetic column 21 cooperate to form a primary magnetic circuit, the secondary winding 40 and the secondary magnetic column 22 cooperate to form a secondary magnetic circuit, and the magnetic block 50, the primary winding 30 and the primary magnetic column 21 cooperate to form a resonant magnetic circuit, thereby integrating the main magnetic circuit and the resonant magnetic circuit on a magnetic core 20 to form a transformer structure with a main-resonant integrated structure.

[0034] The primary winding 30 and the secondary winding 40 are arranged on two magnetic columns arranged at intervals, thereby separating the primary and secondary sides, reducing the heating effect of the magnetic field generated by the large current of the secondary winding 40 on the primary winding 30, and reducing mutual interference. At the same time, the primary winding 30 and the secondary winding 40 are integrated together with the help of the same magnetic core 20, thereby improving the integration of the product.

[0035] The magnetic block 50 is arranged opposite to the primary winding 30, and can absorb the leakage flux caused by the current change of the primary winding 30, play the role of a shield, and reduce the electromagnetic interference to external electrical devices. Therefore, there is no need to set a resonant coil and a resonant magnetic core 20 in the transformer to absorb the leakage inductance, simplifying the structural setting.

[0036] The primary magnetic column 21 and the secondary magnetic column 22 are arranged at intervals, and the cross-sectional areas can be designed separately. Specifically, the cross-sectional areas of the primary magnetic column 21 and the secondary magnetic column 22 are different, so that the magnetic fluxes passing through the primary magnetic column 21 and the secondary magnetic column 22 are inconsistent, maximizing the use of the volume of the magnetic core 20 and reducing costs. Optionally, the cross-sectional area of ​​the primary magnetic column 21 is greater than the cross-sectional area of ​​the secondary magnetic column 22.

[0037] The main-resonant integrated transformer provided in the embodiment of the present invention does not require a resonant coil and a resonant magnetic core 20 as a resonant inductor. The magnetic block 50 and the primary winding 30 are used to absorb leakage magnetic flux, so that the resonant inductor is integrated with the main magnetic circuit, which simplifies the structure and reduces electromagnetic interference. The secondary winding 40 and the primary winding 30 are arranged on different magnetic columns, and there is little interference between them. The cross-sectional areas of the primary magnetic column 21 and the secondary magnetic column 22 are different, which reduces costs and makes full use of the volume of the magnetic core 20.

[0038] like Figure 3 As shown, the primary winding 30 includes a primary frame 31 and a primary coil 32. The primary frame 31 includes a sleeve and a rib. The sleeve is provided with ribs on opposite sides. The sleeve is sleeved on the primary magnetic column 21. The primary coil 32 is wound on the sleeve and limited by the ribs. Figure 4 As shown, the base 10 has a first through hole 11 and a second through hole 12 , one end of the primary coil 32 is passed through the first through hole 11 , and the other end is passed through the second through hole 12 .

[0039] The primary coil 32 is directly wound on the primary frame 31. Compared with the α-coil structure, the winding efficiency is high because the wire is directly wound on the primary frame 31. Figure 3As shown, the primary skeleton 31 is cylindrical, including a sleeve and ribs located at opposite ends of the sleeve, and the ribs and the outer wall of the sleeve are arranged to form an annular groove, which can constrain the winding area of ​​the primary coil 32. The ribs are arranged around the sleeve; or, each section of the sleeve is provided with a plurality of ribs at intervals around the circumference, and the plurality of ribs located at the same end form an outer edge to constrain the winding position of the primary coil 32. In addition, the primary skeleton 31 can also be U-shaped or square-shaped. Optionally, the wall of the sleeve is provided with a plurality of heat dissipation holes, which can promote air flow and assist heat dissipation while reducing the weight of the primary skeleton 31.

[0040] The sleeve is sleeved on the primary magnetic column 21, and one end of the primary coil 32 passes through the first through hole 11, and the other end passes through the second through hole 12, so as to be connected to other circuit structures on the second side of the base 10. The shapes of the first through hole 11 and the second through hole 12 are adapted to the thickness of the primary coil 32. The layout positions of the first through hole 11 and the second through hole 12 ensure that the two ends of the primary coil 32 extend naturally without bending and extending.

[0041] The number of winding layers of the primary coil 32 on the primary frame 31 does not exceed 3. The traditional α-coil structure has a large number of winding layers, which leads to high winding loss under the proximity effect, and the internal heat is not easy to be dissipated and the temperature rises. Therefore, the embodiment of the present invention controls the number of winding layers of the primary coil 32 to not exceed 3 layers, which facilitates glue filling and heat dissipation and improves the heating condition of the product.

[0042] In the main-harmonic integrated transformer provided in the embodiment of the present invention, the primary winding 30 is formed by winding on the primary frame 31, which improves the winding efficiency and controls the number of winding layers of the primary coil 32, thereby improving the heat dissipation effect of the product.

[0043] like Figure 3 As shown, the secondary winding 40 includes a secondary frame 41 and a secondary copper busbar 42. The secondary frame 41 is U-shaped. The secondary copper busbar 42 is sleeved on the secondary frame 41. The base 10 is provided with a socket 13. The open end of the secondary copper busbar 42 is inserted into the socket 13 and extends to the second side of the base 10.

[0044] like Figure 3 As shown, the secondary side frame 41 is U-shaped. In order to reduce the weight of the secondary side frame 41, a plurality of weight-reducing holes are provided on the secondary side frame 41, thereby reducing the overall weight without sacrificing the structural strength. The open end of the secondary side frame 41 is inserted into the base 10, so that the two ends of the secondary side frame 41 are respectively connected to the corresponding sockets 13, thereby forming a closed cavity between the secondary side frame 41 and the base 10, and the secondary side magnetic column 22 is accommodated in the cavity. A card slot is provided on the secondary side frame 41, and the secondary side copper bar 42 is carded in the card slot, which is convenient for assembling and fixing the secondary side copper bar 42.

[0045] In one embodiment, the secondary copper bar 42 has a middle tap, and the number of turns of the secondary winding 40 is adjusted by the middle tap. A gap is left between the two secondary copper bars 42 to reduce heat generation and facilitate glue filling. Figure 5 As shown, the secondary copper bar 42 is a 1:1 winding with a middle tap. The two secondary copper bars 42 are fixed by welding through the connecting terminals for easy connection. Figure 6 As shown, the secondary copper busbar 42 has no center tap.

[0046] like Figure 2 As shown, the magnetic core 20 has a first guide groove 23 and a second guide groove 24 . The first guide groove 23 is arranged corresponding to the primary winding 30 , and the second guide groove 24 is arranged corresponding to the secondary winding 40 .

[0047] like Figure 2 As shown, the first guide groove 23 is a through groove that runs through the opposite sides of the magnetic core 20. The first guide groove 23 forms a gap between the primary frame 31 and the primary magnetic column 21, and the second guide groove 24 forms a gap between the secondary frame 41 and the secondary magnetic column 22, so as to facilitate the flow of glue during potting.

[0048] like Figure 4 As shown, a receiving groove 14 is provided on the second side of the base 10, and clamping holes 15 are respectively provided on the opposite sides of the groove bottom of the receiving groove 14, and protrusions 51 are respectively provided on the opposite sides of the magnetic block 50, and the two protrusions 51 are clamped in the two clamping holes 15 one by one.

[0049] like Figure 4 As shown, the receiving groove 14 is square, and the shape of the magnetic block 50 is consistent with the shape of the receiving groove 14. When installed, the magnetic block 50 is embedded in the receiving groove 14 to prevent the magnetic block 50 from protruding from the base 10. Specifically, the outer surface of the magnetic block 50 is flush with the notch of the receiving groove 14 or slightly lower than the notch of the receiving groove 14. The receiving groove 14 and the primary winding 30 are located on the same side of the base 10, so that the magnetic block 50 cooperates with the primary winding 30 to form a Fig. 9 The magnetic ring shown in the figure has a magnetic flux as Fig.10 shown.

[0050] The receiving groove 14 is provided with a clamping hole 15 on both sides along the width direction, and the magnetic block 50 is provided with a protrusion 51 correspondingly, and the protrusion 51 is clamped in the clamping hole 15, so that the protrusion 51 passes through the base 10 and docks with the primary winding 30. It should be noted that the clamping hole 15 is adapted to the protrusion 51, such as Figure 4 As shown, the clamping hole 15 is a strip hole extending from one wall of the receiving groove 14 to another wall of the receiving groove 14. The size and shape of the magnetic block 50 can be adjusted according to the leakage inductance requirements of different products. Correspondingly, the specifications of the receiving groove 14 on the base 10 are flexibly set according to the size and shape of the magnetic block 50.

[0051] like Figure 3As shown, a vertical plate 16 is provided on the base 10, and the vertical plate 16 is located between the secondary winding 40 and the primary winding 30. Figure 2 As shown, the primary magnetic column 21 and the secondary magnetic column 22 are arranged opposite to each other with a gap in between. After the primary winding 30 is sleeved on the primary magnetic column 21 and the secondary winding 40 is sleeved on the secondary magnetic column 22, there is still a gap between the primary winding 30 and the secondary winding 40. The vertical plate 16 is inserted between the secondary winding 40 and the primary winding 30 for isolation.

[0052] The height of the vertical plate 16 can be lower than the height of either the secondary winding 40 or the primary winding 30. Two vertical plates 16 can be provided, and the two vertical plates 16 are arranged at intervals, one of which is close to the outer wall of the secondary winding 40, and the other vertical plate 16 is close to the outer wall of the primary winding 30, thereby positioning and separating the secondary winding 40 and the primary winding 30 with the help of the two vertical plates 16, reducing the interference between the primary and secondary windings. Optionally, the vertical plate 16 and the base 10 are plastic parts, which are integrally injection molded.

[0053] The present invention provides a vehicle-mounted charger, which includes the main-harmonic integrated transformer as described above. The vehicle-mounted charger also includes other circuit structures that cooperate with the main-harmonic integrated transformer, which will not be described in detail in the embodiments of the present invention.

[0054] In addition, the present invention also provides an electric vehicle, which includes the on-board charger as described above.

[0055] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A main-resonant integrated transformer, characterized in that: include: A base, a magnetic core, a primary winding, a secondary winding and a magnetic block, wherein the magnetic core is fixed to the first side of the base, and the magnetic block can be replaceably installed on the second side of the base and corresponds to the position of the primary winding, and the first side is opposite to the second side; the magnetic core has a primary magnetic column and a secondary magnetic column that are separated from each other, the primary winding is sleeved on the primary magnetic column, and the secondary winding is sleeved on the secondary magnetic column, wherein the cross-sectional areas of the primary magnetic column and the secondary magnetic column are different.

2. The main-harmonic integrated transformer according to claim 1, characterized in that: The primary winding includes a primary frame and a primary coil, the primary frame includes a sleeve and a rib, the ribs are arranged on opposite sides of the sleeve, the sleeve is sleeved on the primary magnetic column, the primary coil is wound on the sleeve and limited by the ribs, the base has a first through hole and a second through hole, one end of the primary coil is passed through the first through hole, and the other end is passed through the second through hole.

3. The main-harmonic integrated transformer according to claim 2, characterized in that: The number of winding layers of the primary coil on the primary frame does not exceed 3.

4. The main-harmonic integrated transformer according to claim 1, characterized in that: The secondary winding includes a secondary frame and a secondary copper bar, the secondary frame is U-shaped, the secondary copper bar is sleeved on the secondary frame, the base is provided with a socket, the open end of the secondary copper bar is inserted into the socket and extends to the second side of the base.

5. The main-harmonic integrated transformer according to claim 4, characterized in that: The secondary copper busbar has a middle tap.

6. The main-harmonic integrated transformer according to claim 5, characterized in that: There is a gap between the two secondary copper bars and they are fixed by welding through connecting terminals.

7. The main-harmonic integrated transformer according to claim 1, characterized in that: The magnetic core has a first guide groove and a second guide groove, the first guide groove is arranged corresponding to the primary winding, and the second guide groove is arranged corresponding to the secondary winding.

8. The main-harmonic integrated transformer according to claim 1, characterized in that: A receiving groove is provided on the second side of the base, and clamping holes are respectively provided on opposite sides of the groove bottom of the receiving groove. Protrusions are respectively provided on opposite sides of the magnetic block, and two protrusions are clamped in the two clamping holes in a one-to-one correspondence.

9. The main-harmonic integrated transformer according to claim 1, characterized in that: A vertical plate is provided on the base, and the vertical plate is located between the secondary winding and the primary winding.

10. A vehicle charger, characterized in that: It comprises the main-harmonic integrated transformer as described in any one of claims 1 to 9.

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