Integrated transformer suitable for switching power supply with large current output

Abstract

The invention belongs to the technical field of transformers, and discloses an integrated transformer suitable for a high-current output switching power supply, a lower magnetic core group is connected to the bottom of an upper magnetic core group, a mounting inner cavity is defined between the upper magnetic core group and the lower magnetic core group, the upper magnetic core group is provided with an upper middle column, and the lower magnetic core group is provided with a lower middle column; the upper middle column corresponds to the lower middle column in position and abuts against the upper middle column to form a mounting column, the peripheral magnetic core set is connected to the bottom of the lower magnetic core set, a peripheral mounting inner cavity is defined between the peripheral magnetic core set and the lower magnetic core set, the peripheral magnetic core set is provided with a peripheral middle column, and the copper sheet wire cake assembly comprises a copper sheet part, a primary wire cake and a peripheral wire cake. The copper sheet parts and the primary wire cakes are sequentially arranged on the mounting column in a staggered mode, the peripheral wire cakes are arranged on the peripheral middle column, and the primary wire cakes and the peripheral wire cakes are connected in series. The device has the advantages that the requirements for low voltage and large current can be met, operation is flexible, and the problems that materials are disordered and purchasing is difficult are effectively avoided.

Description

Technical Field

[0001] The invention relates to the technical field of transformers, and in particular to an integrated transformer suitable for a switching power supply with large current output. Background Art

[0002] Transformers are magnetic core components commonly used in various electrical equipment. They can use the principle of electric energy and magnetic energy conversion induction to adjust different voltages to achieve the applicable range of electrical equipment. Common power supply transformers require multiple transformers, which has a negative impact on PCB layout, space occupation and power density. In addition, some transformers have complex structures, are difficult to wind, and are troublesome to manufacture, which is very unfavorable to the efficient production of enterprises.

[0003] Therefore, it is necessary to provide an integrated transformer suitable for a switching power supply with a large current output, which has a simple structure and high quality and can greatly reduce the labor intensity of workers. Summary of the invention

[0004] The present invention discloses an integrated transformer suitable for a switching power supply with large current output, aiming to solve the problem of high power density requirement of the power supply, which can effectively solve the technical problems involved in the background technology.

[0005] To achieve the above object, the technical solution of the present invention is:

[0006] An integrated transformer suitable for a switching power supply with large current output comprises an upper magnetic core group, a lower magnetic core group, a peripheral magnetic core group and a copper sheet coil assembly, wherein the lower magnetic core group is connected to the bottom of the upper magnetic core group, an installation cavity is enclosed between the upper magnetic core group and the lower magnetic core group, an upper middle column is provided in the installation cavity of the upper magnetic core group, a lower middle column is provided in the installation cavity of the lower magnetic core group, the upper middle column and the lower middle column are positioned correspondingly, and the two are abutted to form an installation column, the peripheral magnetic core group is connected to the bottom of the lower magnetic core group, an outer installation cavity is enclosed between the peripheral magnetic core group and the lower magnetic core group, an outer middle column is provided in the outer installation cavity, and the copper sheet coil assembly comprises a copper sheet portion, a primary coil and an outer coil, the number of the copper sheet portion and the primary coil is multiple, the two are alternately arranged on the installation column in sequence, the outer coil is arranged on the outer middle column, and the primary coil and the outer coil are connected in series.

[0007] The present invention is applicable to the technical field of transformer structure, and provides a transformer structure applicable to a switching power supply with large current output, including three magnetic core groups, a winding sleeve on the center column of the main magnetic core group, the outside of the winding sleeve can be used to place the primary coil and the copper busbar on the center column of the main magnetic core group, the coil is placed between the busbars, and insulating tape is added between the coils, and the coils on the main magnetic core group are connected in series with the coils on the auxiliary magnetic core group. It can effectively avoid the difficulty of operation due to the use of thicker multi-strand twisted wire winding, which is easy to consume labor time and material costs, and also integrate the transformer with the peripheral inductor to reduce the required space.

[0008] As a preferred improvement of the present invention: the number of the copper sheet wire cake assemblies is multiple, the upper magnetic core group is provided with the same number of upper middle columns as the copper sheet wire cake assemblies, the number of the lower middle columns and the outer middle columns is the same as the upper middle columns, and they are arranged in sequence.

[0009] As a preferred improvement of the present invention: the upper magnetic core group, the lower magnetic core group and the peripheral magnetic core group are connected by glue.

[0010] As a preferred improvement of the present invention: the transformer further comprises a fixing member, which is sleeved around the periphery of the upper magnetic core group, the lower magnetic core group and the peripheral magnetic core group and is used to fix the former three.

[0011] As a preferred improvement of the present invention: an insulating mechanism is provided between the copper sheet portion and the primary coil.

[0012] As a preferred improvement of the present invention: the copper sheet portion includes a copper sheet group 1 and a copper sheet group 2, the copper sheet group 1 and the copper sheet group 2 have the same structure, but their protruding directions are opposite.

[0013] As a preferred improvement of the present invention: the copper sheet group one includes two identical bus copper sheets, which are annular and have a notch, and the two ends of the bus copper sheets at the notch are respectively provided with pin one and pin two, and one of the bus copper sheets is flipped 180° and stacked on top of the other bus copper sheet to form the copper sheet group one, and the pin one of the upper bus copper sheet is directly above the pin one of the lower bus copper sheet.

[0014] As a preferred improvement of the present invention: insulating parts are provided on both the upper and lower sides of the busbar copper sheet.

[0015] As a preferred improvement of the present invention: the transformer further comprises a positioning plate, the positioning plate is provided with a plurality of positioning holes, and the positioning holes are arranged corresponding to the positions of the first pin and the second pin.

[0016] As a preferred improvement of the present invention: the copper sheet coil assembly further comprises an elastic insulating limit ring, which is sleeved on the mounting column and used for pressing the copper sheet portion and the primary coil.

[0017] The beneficial effects of the present invention are as follows:

[0018] The present invention can meet the requirements of low voltage and high current without causing waste of labor and materials due to winding difficulties, thereby improving production efficiency, and allowing the transformer and peripheral inductor to be integrated, reducing the burden of high power density requirements, and can greatly improve the utilization rate of the secondary winding. The requirements of different output currents can be met by increasing or decreasing the number of secondary winding copper sheets and the thickness of the copper sheets. The operation is flexible and effectively avoids the problems of material confusion and procurement difficulties. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative work, among which:

[0020] Figure 1 A schematic diagram of an integrated transformer suitable for a switching power supply with a large current output according to the present invention;

[0021] Figure 2 It is a schematic diagram of the transformer decomposition of the present invention;

[0022] Figure 3 This is a schematic diagram of the structure of the copper sheet wire cake assembly of the present invention;

[0023] Figure 4 This is a schematic diagram of the structure of the copper sheet portion of the present invention;

[0024] Figure 5 This is a schematic diagram of the structure of a copper sheet group of the present invention;

[0025] Figure 6 This is an exploded schematic diagram of a copper sheet assembly according to the present invention;

[0026] Figure 7 It is a schematic diagram of the wire cake structure of the present invention.

[0027] In the figure: 100-upper magnetic core group, 110-upper middle column, 200-lower magnetic core group, 210-lower middle column, 300-peripheral magnetic core group, 310-peripheral middle column, 400-copper sheet coil assembly, 410-copper sheet part, 411-copper sheet group one, 4111-bus copper sheet, 4112-pin one, 4113-pin one, 4114-insulating part, 412-copper sheet group two, 420-primary coil, 430-peripheral coil, 500-positioning plate, 600-fixing part. DETAILED DESCRIPTION

[0028] The technical solutions in the embodiments of the present invention will be described clearly and completely below in combination with the embodiments of the present invention. Obviously, the described embodiments are only 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.

[0029] It should be noted that all directional indications in the embodiments of the present invention (such as up, down, left, right, front, back, etc.) are only used to explain the relative position relationship, movement status, etc. between the components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0030] In addition, in the present invention, descriptions such as "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" or "second" may explicitly or implicitly include at least one of the features. In the description of the present invention, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0031] In the present invention, unless otherwise clearly specified and limited, the terms "connection", "fixation", etc. should be understood in a broad sense. For example, "fixation" 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 an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements, unless otherwise clearly defined. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0032] In addition, the technical solutions between the various embodiments of the present invention can be combined with each other, but it must be based on the fact that ordinary technicians in the field can implement it. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0033] See also Figure 1-Figure 3 As shown, the present invention provides an integrated transformer suitable for a switching power supply with a large current output, comprising an upper magnetic core group 100, a lower magnetic core group 200, a peripheral magnetic core group 300 and a copper sheet coil assembly 400, wherein the lower magnetic core group 200 is connected to the bottom of the upper magnetic core group 100, and an installation inner cavity is enclosed between the upper magnetic core group 100 and the lower magnetic core group 200, wherein the upper magnetic core group 100 is provided with an upper middle column 110 in the installation inner cavity, and the lower magnetic core group 200 is provided with a lower middle column 210 in the installation inner cavity, wherein the upper middle column 110 and the lower middle column 210 are located in corresponding positions, and the two are abutted to form an installation column, The peripheral magnetic core group 300 is connected to the bottom of the lower magnetic core group 200. A peripheral installation inner cavity is enclosed between the peripheral magnetic core group 300 and the lower magnetic core group 200. The peripheral magnetic core group 300 is provided with a peripheral middle column 310 in the peripheral installation inner cavity. The copper sheet wire cake assembly 400 includes a copper sheet portion 410, a primary wire cake 420 and a peripheral wire cake 430. The number of the copper sheet portion 410 and the primary wire cake 420 is multiple, and the two are arranged alternately on the installation column in sequence. The peripheral wire cake 430 is arranged on the peripheral middle column 310, and the primary wire cake 420 and the peripheral wire cake 430 are connected in series. The number of the copper sheet wire cake assembly 400 is multiple (3 in this embodiment), and the upper magnetic core group 100 is provided with the same number of upper middle columns 110 as the copper sheet wire cake assembly 400. The number of the lower middle columns 210 and the peripheral middle columns 310 is the same as that of the upper middle column 110, and they are arranged in sequence.

[0034] See also Figure 4-Figure 7 As shown, an insulating mechanism, an insulating plate or a similar structure is provided between the copper sheet portion 410 and the primary coil 420. The copper sheet portion 410 includes a copper sheet group 1 411 and a copper sheet group 2 412. The copper sheet group 1 411 and the copper sheet group 2 412 have the same structure, but the pin-out directions of the two are opposite. The copper sheet group 1 411 includes two identical bus copper sheets 4111, which are annular and have a notch. The two ends of the bus copper sheet 4111 at the notch are respectively provided with a pin 1 4112 and a pin 2 4113. One of the bus copper sheets 4111 is flipped 180° and stacked on top of the other bus copper sheet 4111 to form the copper sheet group 1 411. The pin 1 4112 of the upper bus copper sheet 4111 is directly above the pin 1 4112 of the lower bus copper sheet 4111. Insulating parts 4114 are provided on the upper and lower sides of the bus copper sheet 4111.

[0035] Specifically, the transformer includes two equidistant core groups, a peripheral inductor core group, equidistantly arranged core group middle columns, external busbars, and integrated primary coils and peripheral coils. The outside of the core group middle column can be used to place the primary coils, which are formed by multiple groups of coils connected in series, and insulating tape is provided between the coils and the busbars. After multiple groups of primary coils are connected in series on the two equidistant core groups, they are connected in series with the peripheral coils arranged outside the center column of the peripheral inductor core group. Two busbars are stacked after being flipped 180° in plane, with insulating tape provided between them. The two busbars flipped 180° in plane and stacked are stacked with two busbars rotated 180° horizontally, with the pins in opposite directions. The winding area outside the center column of the equidistant core group can also be wound in parallel with a single coil. That is, the outside of the column in the equidistant core group is used to place the stacked busbar copper sheets, which are four sheets in different directions, and insulating tape is provided between each busbar copper sheet. The outside of the column in the equidistant core group can be used to place the primary coils, which are formed by coils connected in series. The primary series coils placed outside the column in the equidistant core group are then connected in series with the coils placed on the column in the peripheral core group.

[0036] As an implementation mode, the upper magnetic core group 100, the lower magnetic core group 200 and the peripheral magnetic core group 300 are connected by glue, and the transformer also includes a fixing member 600, which is sleeved on the outer periphery of the upper magnetic core group 100, the lower magnetic core group 200 and the peripheral magnetic core group 300, and is used to fix the first three. The transformer also includes a positioning plate 500, and a plurality of positioning holes are provided on the positioning plate 500. The positioning holes are arranged corresponding to the positions of the first pin 4112 and the second pin 4113, which is convenient for stabilizing the bus copper sheet and avoiding contact between the bus copper sheets. The copper sheet wire coil assembly 400 also includes an elastic insulating limiting ring, which is sleeved on the mounting column and is used to compress the copper sheet part 410 and the primary wire coil 420. When the number of wire coils and copper sheets sleeved on the middle column is small, the wire coils and copper sheets will be relatively loose and easy to slide, and the elastic insulating limiting ring is used to prevent them from moving. It should be further explained that the use of other components to achieve the above-mentioned effects should all fall within the inventive concept of the present invention and should fall within the protection scope of the present invention.

[0037] Embodiment 1

[0038] This embodiment provides a transformer structure suitable for a switching power supply with a large current output, including two equidistant core groups (100 and 200 in the figure), a peripheral inductor core group (300 in the figure), a busbar copper sheet outside the center column of the equidistant core group, and an integrated wound coil. The outside of the center column of the equidistant core group is used to place the primary coil, which is formed by connecting multiple groups of coils in series. The outside of the center column of the equidistant core group is used to place the busbar copper sheet. First, place a busbar copper sheet on the center column of the equidistant core group, and then flip the plane of the second busbar copper sheet 180° and place it on the center column of the equidistant core group. Each busbar copper sheet is isolated with insulating tape. At this time, the pins of the two busbar copper sheets are in the same direction. The two busbar copper sheets are defined as a group. Then, a group of busbar copper sheets is used, rotated horizontally 180° and placed on the center column of the equidistant core group. At this time, the pins of the two groups of busbar copper sheets are not in the same direction. Next, place a portion of the primary coil, then place two groups of busbars, and then place a portion of the primary coil, and repeat this process. Finally, after the primary coil and busbars on the equidistant core group are placed, a portion of the primary coil is placed on the center column of the peripheral inductor core group. The winding area outside the center column of the equidistant core group can also be wound with multiple wires in parallel, and the winding on the peripheral inductor core group can also be wound with multiple wires in parallel, and then connected in series with the coil on the equidistant core group, but attention should be paid to the winding direction of each coil.

[0039] Although the embodiments of the present invention have been disclosed as above, they are not limited to the applications listed in the specification and the embodiments. They can be fully applied to various fields suitable for the present invention. For those familiar with the art, additional modifications can be easily implemented. Therefore, without departing from the general concept defined by the claims and the scope of equivalents, the present invention is not limited to the specific details and the illustrations shown and described herein.

Claims

1. An integrated transformer suitable for a switching power supply with large current output, characterized in that: The invention comprises an upper magnetic core group (100), a lower magnetic core group (200), a peripheral magnetic core group (300) and a copper sheet wire cake assembly (400), wherein the lower magnetic core group (200) is connected to the bottom of the upper magnetic core group (100), an installation inner cavity is surrounded between the upper magnetic core group (100) and the lower magnetic core group (200), the upper magnetic core group (100) is provided with an upper middle column (110) in the installation inner cavity, the lower magnetic core group (200) is provided with a lower middle column (210) in the installation inner cavity, the upper middle column (110) and the lower middle column (210) are located in corresponding positions, and the two are abutted to form an installation column, and the peripheral magnetic core group (300) is connected to the lower magnetic core group (100). At the bottom of the magnetic core group (200), a peripheral installation inner cavity is enclosed between the peripheral magnetic core group (300) and the lower magnetic core group (200); the peripheral magnetic core group (300) is provided with a peripheral middle column (310) in the peripheral installation inner cavity; the copper sheet coil assembly (400) comprises a copper sheet portion (410), a primary coil (420) and a peripheral coil (430); the number of the copper sheet portion (410) and the primary coil (420) is plural, and the two are arranged alternately on the installation column in sequence; the peripheral coil (430) is arranged on the peripheral middle column (310), and the primary coil (420) and the peripheral coil (430) are connected in series.

2. The integrated transformer for a switching power supply with large current output according to claim 1, characterized in that: The number of the copper sheet wire cake assemblies (400) is multiple, the upper magnetic core group (100) is provided with the same number of upper middle columns (110) as the number of the copper sheet wire cake assemblies (400), the number of the lower middle columns (210) and the outer middle columns (310) is the same as the number of the upper middle columns (110), and they are arranged in sequence and in correspondence.

3. The integrated transformer for a switching power supply with large current output according to claim 1, characterized in that: The upper magnetic core group (100), the lower magnetic core group (200) and the peripheral magnetic core group (300) are connected by glue.

4. The integrated transformer for a switching power supply with large current output according to claim 1, characterized in that: The transformer further comprises a fixing member (600), wherein the fixing member (600) is sleeved around the periphery of the upper magnetic core group (100), the lower magnetic core group (200) and the peripheral magnetic core group (300), and is used to fix the former three.

5. The integrated transformer for a switching power supply with large current output according to claim 1, characterized in that: An insulating mechanism is provided between the copper sheet portion (410) and the primary coil (420).

6. The integrated transformer for a switching power supply with large current output according to claim 1, characterized in that: The copper sheet portion (410) comprises a copper sheet group 1 (411) and a copper sheet group 2 (412); the copper sheet group 1 (411) and the copper sheet group 2 (412) have the same structure, but their pin-out directions are opposite.

7. The integrated transformer for a switching power supply with large current output according to claim 6, characterized in that: The copper sheet group one (411) comprises two identical bus copper sheets (4111), the bus copper sheets (4111) are annular and provided with a notch, and the two ends of the bus copper sheets (4111) at the notch are respectively provided with a first pin (4112) and a second pin (4113), and one of the bus copper sheets (4111) is flipped 180 degrees and stacked on top of the other bus copper sheet (4111) to form the copper sheet group one (411), and the first pin (4112) of the upper bus copper sheet (4111) is directly above the first pin (4112) of the lower bus copper sheet (4111).

8. The integrated transformer for a switching power supply with large current output according to claim 7, characterized in that: Insulating parts (4114) are provided on both the upper and lower sides of the busbar copper sheet (4111).

9. The integrated transformer suitable for a switching power supply with large current output according to claim 7, characterized in that: The transformer further comprises a positioning plate (500), wherein the positioning plate (500) is provided with a plurality of positioning holes, wherein the positioning holes are arranged corresponding to the positions of the first pin (4112) and the second pin (4113).

10. The integrated transformer for a switching power supply with large current output according to claim 1, characterized in that: The copper sheet coil assembly (400) further comprises an elastic insulating limiting ring, which is sleeved on the mounting column and is used to compress the copper sheet portion (410) and the primary coil (420).

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