Transformer for vehicle-mounted charger of electric vehicle

Abstract

The present invention relates to a transformer for an on-board charger for an electric vehicle, the transformer being used as an on-board charger for an electric vehicle that charges a high-voltage battery of an electric vehicle with common AC power (220V AC) supplied from the charger, the transformer comprising: a housing (110) in which an installation space (Sa) is formed; a cover (120) for opening and closing an installation space (Sa) of the housing (110); a flat-plate-type primary coil (130) that is housed in the housing space (Sa) of the housing (110) and that receives power supplied from the charger side of the electric vehicle; and a plurality of flat-plate-type secondary coils (140) which are housed in the housing space (Sa) of the housing (110), and which generate an induced current from the primary coils (130) independently by magnetic field induction and output the induced current to a high-voltage battery, thereby having the benefits of reducing the size, improving the product productivity, improving the price competitiveness of the product, and having high-voltage insulation characteristics.

Description

Technical Field

[0001] The invention relates to an on-board charger (On Board Charger) of an electric vehicle. Background Art

[0002] Plug in Hybrid electric vehicle (PHEV) and electric vehicle (EV) (hereinafter collectively referred to as electric vehicles) require a charging device that can charge the high voltage battery that drives the vehicle motor with 200V alternating current (AC). This charging device is called an on-board charger.

[0003] An electric vehicle includes an on-board charger for charging a high-voltage battery that drives a vehicle motor with common electricity (200V AC) supplied by the charger; a high-voltage battery for charging the electricity converted by the on-board charger; and a low-voltage DC-DC converter (LDC) that supplies power to the electrical components of the vehicle by converting the high voltage of the high-voltage battery into a low voltage of 12V.

[0004] Furthermore, the on-board charger built into the electric vehicle includes: a first converter, which performs full-wave rectification on the 220V AC power supplied from the charger through a bridge diode, and boosts the full-wave rectified voltage through a boost converter circuit; a second converter, which converts the rectified voltage output from the first converter into a high-frequency AC voltage through a full-bridge circuit; a transformer, which is used to convert the high-frequency AC voltage output from the second converter into a higher voltage and physically insulate the 220V AC power from the high-voltage battery; a rectifier, which rectifies and filters the high-frequency high-voltage AC voltage converted by the transformer, and converts it into a direct current (DC) voltage and supplies it to the high-voltage battery.

[0005] Here, the structure of a transformer for a vehicle charger of the related art will be described.

[0006] In a conventional on-vehicle charger transformer, a primary coil is wound around a special bobbin, and an insulating tape is wound around the wound primary coil for insulation.

[0007] Then, after the insulating tape is wound around the primary coil, the secondary coil is wound around it.

[0008] Then, after the secondary coil is wound, an insulating tape is wound again for insulation.

[0009] Furthermore, when the secondary coil is wound three times, an insulating tape is wound in the middle of the secondary coil each time the secondary coil is wound to insulate it.

[0010] However, the on-board charger transformer for electric vehicles according to the above-mentioned prior art has the following problems.

[0011] First, the transformer product size is very large. Since the secondary coil is wound coaxially with the primary coil wound on the bobbin, there is a problem that the product size becomes larger, which leads to the problem that the overall size of the car charger becomes larger.

[0012] Secondly, since the assembly process of winding the primary coil, then winding the insulating tape to insulate it, then winding the secondary coil on the insulating tape and winding the insulating tape again is repeated, the number of assembly processes increases, which leads to a problem of reduced productivity.

[0013] Third, since the winding of the primary coil and the secondary coil is performed manually, the coil windings are not aligned, resulting in increased loss and deterioration of anti-electromagnetic interference (EMI) performance. Summary of the invention

[0014] Technical problem to be solved by the invention

[0015] The present invention is proposed to solve the above-mentioned problems of the prior art. The object of the present invention is to provide a transformer for an on-board charger of an electric vehicle as follows:

[0016] First, the height of the transformer used in the on-board charger can be reduced, and the volume (size) of the product can be reduced, thereby reducing the occupied space in the electric vehicle and improving the product competitiveness of the on-board charger.

[0017] Second, it can reduce the loss between the primary and secondary coils in the on-board charger of electric vehicles, thereby improving efficiency.

[0018] Third, even if the transformer is small in size, it can supply large current and high voltage.

[0019] Fourth, the primary and secondary coils of the on-board charger transformer can maintain insulation even at high voltages ranging from several kV to tens of kV.

[0020] Fifth, the number of primary and secondary coil assembly processes can be reduced, thereby improving product productivity and price competitiveness.

[0021] Sixth, it can improve the anti-electromagnetic interference performance of the transformer used in the vehicle charger.

[0022] Seventh, the assembly work of the primary side coil and the secondary side coil can be performed very simply, conveniently and accurately at the same time, and there is no need to perform terminal alignment (wiring) work (wiring work) for the primary side coil and the secondary side coil separately.

[0023] Eighth, the cover can be easily, conveniently and firmly fastened to the housing through a simple structure.

[0024] Ninth, even unskilled operators can quickly and accurately perform wiring work on the on-board charger transformer without wiring errors.

[0025] Tenth, it can prevent foreign matter from entering the shell.

[0026] Eleventh, even if the cover is thin, the strength of the cover can be maintained, so the material cost can be saved and the durability of the product can be improved,

[0027] Twelfth, while insulating the primary side coil and the secondary side coil or insulating the secondary side coils from each other, the primary side coil and the secondary side coil stacked in the vertical direction can be easily, conveniently and accurately aligned longitudinally.

[0028] Thirteenth, the wiring operation between the transformer and other components in the vehicle charger can be performed more easily and conveniently.

[0029] Technical solutions to the problem

[0030] In order to achieve the above-mentioned object, the transformer for an on-board charger of an electric vehicle of the present invention is used as an on-board charger of an electric vehicle for charging a high-voltage battery of the electric vehicle with a common alternating current (220V AC) supplied from a charger of the electric vehicle, and is characterized in that it includes: a housing, which is formed with a loading space; a cover, which is used to open and close the loading space of the housing; a primary side coil, which is built into the loading space of the housing, and receives current provided from the charger of the electric vehicle; a plurality of secondary side coils, which are built into the loading space of the housing, and generate induced currents from the primary side coils independently through magnetic field induction, and output them to the high-voltage battery; an upper magnetic core, which wraps the outer surface of the housing from the upper side of the cover; The lower magnetic core wraps the outer surface of the shell from the lower surface of the shell, the primary side coil is composed of a first adhesive coated conductor, in which a copper wire is coated with an insulating tape, and an adhesive layer is formed by applying an adhesive to the outer peripheral surface of the coated insulating tape. After the first adhesive coated conductor is wound multiple times by a winding member to form a first central hole in the center, the applied adhesive layer is melted and solidified, so that the first adhesive coated conductors that are tightly wound are joined to each other by welding and formed in a coil shape.

[0031] Effects of the Invention

[0032] The on-board charger transformer for electric vehicles of the present invention having the above-mentioned structure has the following effects:

[0033] First, the height of the transformer for the on-board charger can be reduced, and the volume (size) of the product can be reduced, thereby reducing the occupied space in the electric vehicle and improving the product competitiveness of the on-board charger.

[0034] Second, the efficiency can be improved by reducing the loss between the primary and secondary coils in the on-board charger of electric vehicles.

[0035] Third, even if the transformer is small in size, it can supply large current and high voltage.

[0036] Fourth, the primary and secondary coils of the on-board charger transformer can maintain insulation even at high voltages ranging from several kV to tens of kV.

[0037] Fifth, the number of primary and secondary coil assembly processes can be reduced, thereby improving product productivity and price competitiveness.

[0038] Sixth, the anti-electromagnetic interference performance of the transformer used in the vehicle charger can be improved.

[0039] Seventh, the assembly work of the primary side coil and the secondary side coil can be performed very simply, conveniently and accurately at the same time, and there is no need to perform terminal alignment (wiring) work (wiring work) for the primary side coil and the secondary side coil separately.

[0040] Eighth, the cover can be easily, conveniently and firmly fastened to the housing through a simple structure.

[0041] Ninth, even unskilled workers can quickly and accurately perform wiring work on the transformer for the on-board charger without making wiring errors.

[0042] Tenth, it can prevent foreign matter from entering the interior of the housing.

[0043] Eleventh, even if the cover is thin, the strength of the cover can be maintained, so the material cost can be saved and the durability of the product can be improved.

[0044] Twelfth, while insulating the primary side coil and the secondary side coil or insulating the secondary side coils from each other, the primary side coil and the secondary side coil stacked in the vertical direction can be easily, conveniently and accurately aligned longitudinally.

[0045] Thirteenth, the wiring operation between the transformer and other components in the vehicle charger can be performed more easily and conveniently. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Figure 1 FIG. 1 is a perspective view of a transformer 100 for an on-board charger of an electric vehicle according to an embodiment of the present invention.

[0047] Figure 2 for Figure 1 sectional view of .

[0048] Figure 3 for Figure 1 Exploded three-dimensional diagram.

[0049] Figure 4 Part (a) is a right side view of the on-vehicle charger transformer 100 from which the magnetic cores M and M2 are removed, viewed from the position where the input and output wires of the primary side coil 130 are located. Figure 4 Part (b) is a left side view of the vehicle charger transformer 100 with the magnetic cores M and M2 removed, viewed from the position where the input and output wires of the secondary side coil 140 are located.

[0050] Figure 5 Part (a) is a conceptual diagram of the appearance structure of the thin copper wires 130a and 140a when the wires are composed of thin copper wires 130a and 140a. Figure 5 Part (b) is a conceptual diagram of the cross-section of the first and second adhesive coated conductors 130' and 140'. Figure 5 Part (c) is a conceptual diagram of the appearance of the first and second adhesive-type covered conductors 130 ′ and 140 ′ showing a plurality of exposed thin copper wires Li.

[0051] Description of Reference Numerals

[0052] 100: Transformer for an on-board charger of an electric vehicle according to an embodiment of the present invention

[0053] M1: upper core M1a: mid-leg of upper core

[0054] M2: Lower core M2a: Mid-leg of lower core

[0055] 110: Shell Sa: Enclosure space

[0056] 111: bottom 111a: bottom through hole

[0057] 112: peripheral part 113: insertion tube

[0058] 114a: Primary side lead-out slit 114b: Secondary side lead-out slit

[0059] d1: Depth of the lead-out slit on the primary side d2: Depth of the lead-out slit on the secondary side

[0060] 115a: 1st guide rail 115b: 2nd guide rail

[0061] 116a: 1st hanging end 116b: 2nd hanging end

[0062] 117a: first guide inclined surface 117b: second guide inclined surface

[0063] 120: Cover 120a: Cover through hole

[0064] 121: 1st hook 122: 2nd hook

[0065] 123: shielding rod

[0066] 124a: 1st reinforcing rib 124b: 2nd reinforcing rib

[0067] 125a: first twist preventing rib 125b: second twist preventing rib

[0068] 130: 1st secondary coil C1: 1st center hole

[0069] 130': No. 1 bonded coated conductor

[0070] Li: thin copper wire 130a: thin copper wire electric wire

[0071] 130b: Insulation tape 130c: Adhesive layer

[0072] 131: 1st input wire section

[0073] 132: 1st side winding part 133: 1st output wire part

[0074] 134: First input terminal 134a: First input terminal fixing hole

[0075] 135: First output terminal 135a: First output terminal fixing hole

[0076] 140: Secondary coil C2: Second center hole

[0077] 140': Second bonding type coated conductor

[0078] Li: thin copper wire 140a: thin copper wire wire

[0079] 140b: Insulation tape 140c: Adhesive layer

[0080] 141: Second input wire section 142: Secondary side winding section

[0081] 143: Second output cable section

[0082] 144: Second input terminal 144a: Second input terminal fixing hole

[0083] 145: Second output terminal 145a: Second output terminal fixing hole

[0084] 151: first adhesive sheet 151a: first through hole

[0085] 152: Second adhesive sheet 152a: Second through hole

[0086] 210: Heat generating shell Sb: Internal space DETAILED DESCRIPTION

[0087] The preferred embodiments of the transformer for an on-board charger of an electric vehicle of the present invention will be described in detail below with reference to the accompanying drawings.

[0088] A transformer 100 for an on-board charger of an electric vehicle according to an embodiment of the present invention is used as an on-board charger of an electric vehicle for charging a high-voltage battery of the electric vehicle with a common alternating current (220V AC) supplied from a charger of the electric vehicle, and is characterized in that it includes: a housing 110, which is formed with a loading space Sa; a cover 120, which is used to open and close the loading space Sa of the housing 110; a flat primary side coil 130, which is built into the loading space Sa of the housing 110 and receives current provided from the charger of the electric vehicle; a plurality of flat secondary side coils 140, which are built into the loading space Sa of the housing 110, and induction currents are generated independently from the primary side coils 130 through magnetic field induction and output to the high-voltage battery; an upper magnetic core M1, which wraps the upper side of the housing 110 from the upper side of the cover 120; and a lower magnetic core M2, which wraps the lower side of the housing 110 from the lower surface of the housing 110.

[0089] Furthermore, the primary side coil 130 is characterized in that after the first adhesive coated conductor 130' is wound multiple times using a winding member (not shown) to form a first central hole C1 in the center, the coated adhesive layer 130c is melted using a solvent (e.g., ethanol) or is melted by heating (or hot air) and then solidified, so that the first adhesive coated conductors 130' wound tightly together are joined to each other by welding and formed into a hard state (without unevenness on the outer surface) and formed in a coil shape.

[0090] Thus, even at a high voltage of several kV to several tens of kV, the efficiency between the primary side coil and the secondary side coil can be maintained without causing insulation breakdown.

[0091] The wire winding member may use a winding jig or a winder.

[0092] The adhesive may consist of an adhesive coating.

[0093] The insulating tape 130 b may be made of a polyimide tape.

[0094] As described above, the on-board charger transformer 100 of the electric vehicle according to one embodiment of the present invention is used to convert the high-frequency AC voltage output from the second converter of the on-board charger into a high voltage and to physically insulate the 220V AC power from the high-voltage battery.

[0095] The primary side coil 130 includes: a first input wire portion 131, which is connected to the charger side of the electric vehicle (specifically, the second converter of the on-board charger) and is formed by a linear first adhesive coated wire 130'; a primary side winding portion 132, which extends from the first input wire portion 131 and winds the first adhesive coated wire 130' in a flat shape multiple times to form a first central hole C1 in the center; and a first output wire portion 133, which is formed by the linear first adhesive coated wire 130' and is connected to the charger side of the electric vehicle at the terminal of the primary side winding portion 132.

[0096] In the primary side winding portion 132, a winding member is used to automatically wind in a flat plate shape so that the first adhesive-type covered conductors 130' are closely attached to each other and aligned in the horizontal direction and / or vertical direction (that is, this is a concept including the horizontal direction and the vertical direction, or any direction of the vertical direction or the vertical direction), and then the applied adhesive is melted using a solvent (for example, ethanol) or melted by heating (or hot air) and then solidified, so that the first adhesive-type covered conductors 130' are bonded to each other by welding and formed into a hard state in which they are aligned (there is no unevenness on the outer surface).

[0097] Thus, by configuring the primary side coil 130 and the secondary side coil 140 of the vehicle charger transformer in a flat plate shape and housing them in one housing, the height of the vehicle charger transformer can be reduced, and the product size can be reduced.

[0098] Furthermore, the loss between the primary side coil and the secondary side coil in the on-board charger of the electric vehicle can be reduced, thereby improving efficiency.

[0099] In the secondary side coil 140, an insulating tape 140b is used to cover a copper wire to form an outer skin, and an adhesive is coated (coated) on the outer peripheral surface of the insulating tape 140b forming the outer skin to configure a second adhesive coated conductor 140' having an adhesive layer 140c. After the second adhesive coated conductor 140' is wound multiple times using a winding member (not shown) to form a second center hole C2 in the center, the coated adhesive layer 140c is melted using a solvent (e.g., ethanol) or is melted by heating (or hot air) and then solidified, so that the second adhesive coated conductors 140' tightly wound together are joined to each other by welding and formed in a coil shape.

[0100] Furthermore, after the second adhesive coated conductor 140' is wound multiple times using a winding member to form a second center hole C2 in the center, the coated adhesive layer 140c is melted using a solvent (e.g., ethanol) or is melted and solidified by heating (or hot air), so that the second adhesive coated conductors 140' wound tightly together are joined to each other by welding and formed into a solid state of alignment (no unevenness on the outer surface) and formed in a coil shape.

[0101] The secondary side coil 140 includes: a second input wire portion 141, which is connected to the charger side of the electric vehicle (specifically, the second converter of the on-board charger) and is formed by a linear second adhesive coated wire 140'; a secondary side winding portion 142, which extends from the second input wire portion 141 and is formed by winding the second adhesive coated wire 140' in a flat shape multiple times to form a second central hole C2 in the center; and a second output wire portion 143, which is formed by the linear second adhesive coated wire 140' and is connected to the charger side of the electric vehicle at the terminal of the secondary side winding portion 142.

[0102] After the second adhesive coated conductor 140' is wound multiple times using a winding member to form a second central hole C2 in the center, the coated adhesive layer 140c is melted using a solvent (e.g., ethanol) or is melted and solidified by heating (or hot air), so that the second adhesive coated conductors 140' wound tightly together are welded together and formed into a solid state of alignment (no unevenness on the outer surface) and formed in a coil shape.

[0103] According to the specific structures of primary side coil 130 and secondary side coil 140 as described above, a large current and a high voltage can be supplied in a small size.

[0104] As described above, the primary side coil 130 and the secondary side coil 140 of the vehicle charger transformer are formed by self-fusion, so the adhesion between the primary side coil 130 and the secondary side coil 140 of the vehicle charger transformer itself is increased, and the adhesion between the primary side coil 130 and the secondary side coil 140 is also increased, so that the loss is reduced, thereby further improving the efficiency, and the height of the product can be further reduced (can be reduced by 70% compared with the existing vehicle charger transformer), and the size of the product can be further reduced (can be reduced by 70% compared with the existing vehicle charger transformer).

[0105] Furthermore, since the height of the transformer for the on-board charger is reduced and the size of the product is reduced, the size of the on-board charger itself can be reduced, thereby reducing the occupied space and weight in the electric vehicle, thereby improving the product competitiveness of the on-board charger in the electric vehicle.

[0106] Furthermore, as described above, the primary side coil 130 and the secondary side coil 140 of the vehicle charger transformer can be manufactured using a winding jig or a winding machine, so the production of the primary side coil 130 and the secondary side coil 140 of the vehicle charger transformer can be automated, thereby reducing the assembly process (the assembly process is reduced by 50% compared to the existing production process of the vehicle charger transformer), and productivity can be significantly improved, thereby improving price competitiveness.

[0107] On the other hand, any known conductive wire may be included as the covering object of the insulating tapes 130b and 140b.

[0108] That is, the copper wire of the primary side coil 130 can be composed of a copper wire as a bare copper wire, or can be composed of a thin copper wire wire 130a made by twisting multiple strands of thin copper wires Li, or can be composed by insulating the copper wire as a bare copper wire or the thin copper wire wire 130a, and either case falls within the technical scope of the present invention.

[0109] Similarly, the copper wire of the secondary side coil 140 can be composed of a copper wire as a bare copper wire, or can be composed of a thin copper wire wire 140a made by twisting multiple strands of thin copper wires Li, or can be composed by insulating the copper wire as a bare copper wire or the thin copper wire wire 140a. In any case, it falls within the technical scope of the present invention.

[0110] The primary coil 130 is wound so that the first input wire portion 131 and the first output wire portion 133 are both oriented toward the charger side of the electric vehicle, and the secondary coil 140 is wound so that the second input wire portion 141 and the second output wire portion 143 are both oriented toward the same direction.

[0111] The housing 110 includes: a flat bottom 111; an outer portion 112, which is formed upright from the bottom 111; an insertion tube 113, which is formed to protrude upward from the bottom 111, and the loading space Sa is formed by the space between the insertion tube 113 and the outer portion 112, and a pair of primary side lead-out slits 114a are formed at intervals on the left side of the outer portion 112, and the upper sides of which are open and recessed downward, and a pair of secondary side lead-out slits 114b are formed at intervals on the right side of the outer portion 112, and the upper sides of which are open and recessed downward.

[0112] The primary side coil 130 is configured as follows: the primary side winding portion 132 descends in a top-to-bottom direction so that the first central hole C1 is inserted outwardly of the insertion tube 113 and inserted between the outer portion 112 and the insertion tube 113, while the pair of first input wire portions 131 and first output wire portions 133 also descend simultaneously with the primary side winding portion 132 and are inserted into the primary side lead-out slit 114a while descending from top to bottom.

[0113] The secondary side coil 140 is configured as follows: the secondary side winding portion 142 descends in a top-to-bottom direction so that the second central hole C2 is inserted outwardly toward the insertion tube 113 and inserted between the outer portion 112 and the insertion tube 113, while the pair of second input wire portions 141 and second output wire portions 143 also descend simultaneously with the secondary side winding portion 142 and are inserted into the secondary side lead-out slit 114b while descending from top to bottom.

[0114] As described above, since the primary side coil 130 and the secondary side coil 140 can be inserted while descending from top to bottom along the primary side lead-out slit 114a and the secondary side lead-out slit 114b, the operation of inserting the primary side coil 130 and the secondary side coil 140 into the housing 110 is very simple, convenient, and can be performed accurately at the same time, and since there is no need to perform terminal alignment (wiring) operation (wiring operation) for the primary side coil 130 and the secondary side coil 140 separately, the assembly workability is further improved.

[0115] The transformer 100 for an on-board charger of an electric vehicle according to an embodiment of the present invention is characterized in that a first guide rail 115a is formed on the left side of the outer portion 112 between the pair of primary side lead-out slits 114a, and is recessed toward the center direction where the coil is located. A second guide rail 115b is formed on the right side of the outer portion 112 between the pair of secondary side lead-out slits 114b, and is recessed toward the center direction where the coil is located. A first hanging end 115a is formed that protrudes inwardly to form a step difference. 116a, a second hanging end 116b protruding inward to form a step difference is formed on the second guide rail 115b, and also includes: a first hook 121, which is formed vertically downward at the left side end of the cover 120, descends along the first guide rail 115a and is hung and fastened with the first hanging end 116a in a hook manner; a second hook 122, which is formed vertically downward at the right side end of the cover 120, descends along the second guide rail 115b and is hung and fastened with the second hanging end 116b in a hook manner.

[0116] Thus, the cover 120 can be easily, conveniently and firmly fastened to the housing 110 through a simple structure.

[0117] The transformer 100 for an on-board charger of an electric vehicle according to an embodiment of the present invention is characterized in that the first guide rail 115a on the upper side of the first hanging end 116a also includes a first guide inclined surface 117a: the inclined surface is formed so that the width becomes narrower from top to bottom, so that the first hook 121 can be smoothly hung and fastened to the first hanging end 116a, and the second guide rail 115b on the upper side of the second hanging end 116b also includes a second guide inclined surface 117b: the inclined surface is formed so that the width becomes narrower from top to bottom, so that the second hook 122 can be smoothly hung and fastened to the second hanging end 116b.

[0118] Thus, the cover 120 can be fastened to the housing 110 more easily, conveniently and smoothly.

[0119] The primary side coil 130 is arranged below the secondary side coil 140, and the depth d1 of the primary side lead-out gap 114a is formed to be deeper than the depth d2 of the secondary side lead-out gap 114b. The depth d1 of the primary side lead-out gap 114a is formed to be deeper than the depth d2 of the secondary side lead-out gap 114b so that the primary side and the secondary side of the transformer can be identified.

[0120] Thus, even an unskilled operator can quickly and accurately perform the wiring work of the vehicle charger transformer 100 without making wiring errors, thereby improving productivity.

[0121] The transformer 100 for an on-board charger of an electric vehicle according to an embodiment of the present invention is characterized in that it also includes a shielding rod 213: which is formed vertically downward at the left end of the cover 120 corresponding to the position of the pair of primary side lead-out slits 114a, and when the cover 120 is fastened to the housing 110, it descends along the primary side lead-out slit 114a to guide the cover 120 to be fastened by the descent of the housing 110, while preventing foreign matter from entering the primary side lead-out slit 114a.

[0122] Thus, the operation of lowering the cover 120 and assembling it to the housing 110 can be performed accurately, conveniently, and quickly, and foreign matter can be prevented from entering the interior of the housing.

[0123] The transformer 100 for an on-board charger of an electric vehicle according to an embodiment of the present invention is characterized in that it further includes: a first reinforcing rib 124a, which is formed protrudingly on the upper surface of the cover 120 so as to be located directly above the first hook 121 when the cover 120 is fastened to the housing 110, and is used to prevent the first hook 121 from bending when the cover 120 is fastened to the housing 110; a second reinforcing rib 124b, which is formed protrudingly on the upper surface of the cover 120 so as to be located directly above the second hook 122 when the cover 120 is fastened to the housing 110, and is used to prevent the second hook 122 from bending when the cover 120 is fastened to the housing 110.

[0124] Furthermore, the transformer 100 for an on-board charger of an electric vehicle according to an embodiment of the present invention is characterized in that it also includes: a first anti-twist rib 125a, which is formed in a rod shape in the front and rear directions on the upper surface of the cover 120 in a T-shape from the end of the first reinforcing rib 124a, so as to prevent the cover 120 from being twisted when the upper magnetic core M1 is inserted into the insertion tube 113; and a second anti-twist rib 125a, which is formed in a rod shape in the front and rear directions on the upper surface of the cover 120 in a T-shape from the end of the second reinforcing rib 124b, so as to prevent the cover 120 from being twisted when the upper magnetic core M1 is inserted into the insertion tube 113.

[0125] Thereby, even if the cover is thin, the strength of the cover can be maintained, so the material cost can be saved and the durability of the product can be improved.

[0126] The transformer 100 for an on-board charger of an electric vehicle according to an embodiment of the present invention is characterized in that it also includes: a first adhesive sheet 151 having a first through hole 151a formed in the center thereof so as to be inserted outwardly into the insertion tube 113, being interposed and formed between the primary side coil 130 and the secondary side coil 140 inserted adjacent to the primary side coil 130, insulating the primary side coil 130 from the secondary side coil 140, and bonding the primary side coil 130 and the secondary side coil 140 together; and one or more second adhesive sheets 152 having a second through hole 152a formed in the center thereof so as to be inserted outwardly into the insertion tube 113, insulating the plurality of secondary side coils 140 from each other and bonding the secondary side coils 140 together.

[0127] Thus, while insulating the primary side coil 130 and the secondary side coil 140, or insulating the secondary side coil 140, the longitudinal alignment operation of the primary side coil 130 and the secondary side coil 140 stacked in the vertical direction (height direction) can be easily, conveniently and accurately performed.

[0128] A transformer 100 for an on-board charger of an electric vehicle according to an embodiment of the present invention is characterized in that a bottom through hole 111a is formed in the center of the bottom 111, the insertion tube 113 is formed upward along the inner circumference of the bottom through hole 111a, a cover through hole 120a is formed in the center of the cover 120 opposite to the bottom through hole 111a, the middle foot M1a of the upper magnetic core M1 is inserted into the insertion tube 113 through the cover through hole 120a, and the middle foot M2a of the lower magnetic core M2 is inserted into the insertion tube 113 through the bottom through hole 111a.

[0129] The transformer 100 for an on-board charger of an electric vehicle according to an embodiment of the present invention is characterized in that it also includes: a first input terminal 134, which is conductively connected to the end of the first input wire part 131 and has a first input terminal fixing hole 134a; a first output terminal 135, which is conductively connected to the end of the first output wire part 133 and has a first output terminal fixing hole 135a; a second input terminal 144, which is conductively connected to the end of the second input wire part 141 and has a second input terminal fixing hole 144a; and a second output terminal 145, which is conductively connected to the end of the second output wire part 143 and has a second output terminal fixing hole 145a.

[0130] This makes it possible to more easily and conveniently perform the wiring work of the transformer 100 in the vehicle charger.

[0131] The thin copper wire 130a of the first adhesive coated conductor 130' can be formed by twisting 1000 to 2500 thin copper wires Li with a diameter of 0.03 to 0.10 mm. More preferably, the thin copper wire 130a can be formed by twisting 1300 to 2000 thin copper wires Li with a diameter of 0.04 to 0.08 mm.

[0132] The second adhesive coated conductor 140' of the secondary coil 140 can be formed by twisting 1000 to 2500 thin copper wires Li with a diameter of 0.03 to 0.10 mm. More preferably, the thin copper wire electric wire 130a can be formed by twisting 1300 to 2000 thin copper wires Li with a diameter of 0.04 to 0.08 mm.

[0133] This allows high current and high voltage performance to be achieved through the optimal thickness and number of fine copper wires.

[0134] The preferred embodiments of the present invention have been observed above. In addition to the embodiments described above, it is obvious that a person skilled in the art can implement the present invention in other specific embodiments without changing the technical concept or essential features of the present invention. Therefore, the above embodiments should be understood as exemplary rather than restrictive.

[0135] The scope of the present invention is embodied by the appended claims rather than the above detailed description, and all changes or modifications derived from the meaning, scope and equivalent concepts of the claims should be interpreted as being included in the scope of the present invention.

Claims

1. A transformer for an on-board charger of an electric vehicle, which is used as an on-board charger of an electric vehicle for charging a high-voltage battery of the electric vehicle with a common AC power (220V AC) supplied from a charger of the electric vehicle, characterized in that: include: A housing (110) formed with a housing space (Sa); a cover (120) for opening and closing the loading space (Sa) of the housing (110); A flat primary coil (130) is built into the housing space (Sa) of the housing (110) and receives current supplied from a charger of the electric vehicle; A plurality of flat secondary coils (140) are built into the housing space (Sa) of the housing (110), and independently generate induced currents from the primary coils (130) through magnetic field induction, and output them to the high voltage battery; an upper magnetic core (M1) wrapping the upper side of the housing (110) from the upper side of the cover (120); a lower magnetic core (M2) which wraps around the lower side of the housing (110) from the lower surface of the housing (110), The primary side coil (130) is composed of a first adhesive coated conductor (130'), in which a copper wire is coated with an insulating tape (130b), and an adhesive layer (130c) is formed by applying an adhesive to the outer peripheral surface of the insulating tape (130b). After the first adhesive coated wire (130') is wound multiple times by a winding member to form a first central hole (C1) in the center, the coated adhesive layer (130c) is melted and solidified, so that the first adhesive coated wires (130') wound closely together are welded and joined to each other while being aligned and firmly formed in a coil shape.

2. The transformer for an on-board charger of an electric vehicle according to claim 1, characterized in that: The primary side coil (130) includes: A first input wire section (131) connected to the charger side of the electric vehicle and formed by a linear first adhesive coated wire (130'); a primary winding portion (132) extending from the first input wire portion (131) and used to wind the first adhesive coated wire (130') in a flat plate shape multiple times to form a first central hole (C1) in the center; and The first output wire section (133) is formed by a linear first adhesive coated wire (130') and is connected to the charger side of the electric vehicle at the terminal of the primary winding section (132). The primary side winding portion (132) is automatically wound in a flat plate shape by a winding fixture, so that the first adhesive coated wires (130') are closely attached to each other and aligned in the horizontal direction and / or vertical direction, and then the applied adhesive layer (130c) is melted and solidified, so that the first adhesive coated wires (130') are joined to each other by welding and formed into an aligned and solid state.

3. The transformer for an on-board charger of an electric vehicle according to claim 1, characterized in that: The secondary coil (140) is composed of a second adhesive coated conductor (140'), in which the copper wire is coated with an insulating tape (140b), and an adhesive layer (140c) is formed by applying an adhesive to the outer peripheral surface of the coated insulating tape (140b). After the second adhesive coated wire (140') is wound multiple times by a winding member to form a second central hole (C2) in the center, the coated adhesive layer (140c) is melted and solidified, so that the second adhesive coated wires (140') wound closely together are joined to each other by welding and formed into a coil shape.

4. The transformer for an on-board charger of an electric vehicle according to claim 3, characterized in that: The secondary side coil (140) includes: A second input wire portion (141) connected to the charger side of the electric vehicle and formed by a linear second adhesive coated wire (140'); A secondary winding portion (142) extending from the second input wire portion (141) and used to wind the second adhesive coated wire (140') in a flat plate shape multiple times to form a second central hole (C2) in the center; The second output wire section (143) is formed by a linear second adhesive coated wire (140') and is connected to the charger side of the electric vehicle at the terminal of the secondary winding section (142). After the second adhesive coated wire (140') is wound multiple times using a winding member to form a second central hole (C2) in the center, the coated adhesive layer (140c) is melted and solidified, so that the second adhesive coated wires (140') wound closely together are welded and joined to each other while being aligned and firmly formed, and are formed in a coil shape.

5. The transformer for an on-board charger of an electric vehicle according to claim 4, characterized in that: The primary side coil (130) is wound so that the first input wire portion (131) and the first output wire portion (133) are both arranged toward the charger side of the electric vehicle in the same direction. The secondary side coil (140) is arranged such that the second input wire portion (141) and the second output wire portion (143) are oriented in the same direction. The housing (110) comprises: a flat bottom (111); a peripheral portion (112) formed upright upward from the bottom portion (111); An insertion tube (113) is formed to protrude upward from the bottom (111), The loading space (Sa) is formed by the space between the insertion tube (113) and the outer peripheral portion (112). A pair of primary side lead-out slits (114a) are formed at intervals on the left side of the outer peripheral portion (112), and the upper sides thereof are opened and formed to be concave downward. A pair of secondary side lead-out slits (114b) are formed at intervals on the right side of the outer peripheral portion (112), and the upper sides thereof are opened and formed to be concave downward. The primary side coil (130) is configured such that: the primary side winding portion (132) descends in a top-down direction so that the first central hole (C1) is inserted outside the insertion tube (113) and inserted between the outer portion (112) and the insertion tube (113), and at the same time, the pair of first input wire portions (131) and first output wire portions (133) are also descended simultaneously with the primary side winding portion (132) and inserted into the primary side lead-out slit (114a) while descending from top to bottom. The secondary side coil (140) is configured such that: the secondary side winding portion (142) descends in a top-to-bottom direction so that the second central hole (C2) is inserted outwardly of the insertion tube (113) and inserted between the outer portion (112) and the insertion tube (113), and at the same time, the pair of second input wire portions (141) and second output wire portions (143) also descend simultaneously with the secondary side winding portion (142) and are inserted into the secondary side lead-out slit (114b) while descending from top to bottom.

6. The transformer for an on-board charger of an electric vehicle according to claim 5, characterized in that: A first guide rail (115a) is formed on the left side of the outer portion (112) between the pair of primary side lead-out slits (114a) and is recessed toward the center where the coil is located. A second guide rail (115b) is formed on the right side of the outer portion (112) between the pair of secondary side lead-out slits (114b) and is recessed toward the center where the coil is located. The first guide rail (115a) is formed with a first hooking end (116a) protruding inward to form a step difference. The second guide rail (115b) is formed with a second hooking end (116b) protruding inward to form a step difference. Also includes: A first hook (121) is formed vertically downward at the left end of the cover (120), descends along the first guide track (115a) and is hooked and fastened to the first hooking end (116a); and The second hook (122) is formed vertically downward at the right side end of the cover (120), descends along the second guide rail (115b) and is hooked and fastened to the second hooking end (116b).

7. The transformer for an on-board charger of an electric vehicle according to claim 6, characterized in that: The first guide rail (115a) on the upper side of the first hanging end (116a) further includes a first guide inclined surface (117a): the first guide inclined surface (117a) is inclined so that the width becomes narrower from top to bottom, so that the first hook (121) can be smoothly hung and fastened to the first hanging end (116a). The second guide rail (115b) on the upper side of the second hanging end (116b) further includes a second guide inclined surface (117b): the inclined surface is formed so that the width becomes narrower from top to bottom, so that the second hook (122) can be smoothly hung and fastened to the second hanging end (116b).

8. The transformer for an on-board charger of an electric vehicle according to claim 5, characterized in that: The primary side coil (130) is disposed below the secondary side coil (140). The depth (d1) of the primary side lead-out slit (114a) is formed to be deeper than the depth (d2) of the secondary side lead-out slit (114b), The depth (d1) of the primary side lead-out slit (114a) is formed to be deeper than the depth (d2) of the secondary side lead-out slit (114b) so that the primary side and the secondary side of the transformer can be distinguished.

9. The transformer for an on-board charger of an electric vehicle according to claim 5, characterized in that: It also includes a shielding rod (213): the shielding rod (213) is formed vertically downward at the left end of the cover (120) corresponding to the position of the pair of primary side lead-out slits (114a), and when the cover (120) is fastened to the housing (110), it descends along the primary side lead-out slit (114a) to guide the cover (120) to be fastened by the descent of the housing (110), while preventing foreign matter from entering the primary side lead-out slit (114a).

10. The transformer for an on-board charger of an electric vehicle according to claim 6, characterized in that: Also includes: a first reinforcing rib (124a) protruding from the upper surface of the cover (120) so as to be located directly above the first hook (121) when the cover (120) is fastened to the housing (110) and used to prevent the first hook (121) from bending when the cover (120) is fastened to the housing (110); A second reinforcing rib (124b) is formed protruding from the top of the cover (120) so as to be located directly above the second hook (122) when the cover (120) is fastened to the housing (110), and is used to prevent the second hook (122) from bending when the cover (120) is fastened to the housing (110).

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