An integrated transformer suitable for use in a switching power supply for high current output

Abstract

The application belongs to the technical field of transformers, and discloses an integrated transformer suitable for a switching power supply with large current output, wherein a lower magnetic core group is connected to the bottom of an upper magnetic core group, the upper magnetic core group and the lower magnetic core group jointly enclose an installation inner cavity, the upper magnetic core group is provided with an upper middle column, the lower magnetic core group is provided with a lower middle column, the upper middle column and the lower middle column are in position correspondence, and the two abut to form an installation column, a peripheral magnetic core group is connected to the bottom of the lower magnetic core group, the peripheral magnetic core group and the lower magnetic core group jointly enclose a peripheral installation inner cavity, the peripheral magnetic core group is provided with a peripheral middle column, a copper sheet wire cake assembly comprises a copper sheet part, a primary wire cake and a peripheral wire cake, the number of the copper sheet part and the primary wire cake is multiple, the two are sequentially and staggeredly arranged on the installation column, the peripheral wire cake is arranged on the peripheral middle column, and the primary wire cake and the peripheral wire cake are connected in series. The application has the beneficial effects that the low-voltage and large-current requirements can be met, the operation is flexible, and the problems of material confusion and procurement difficulty can be effectively avoided.

Description

Technical Field

[0001] This invention relates to the field of transformer technology, and more particularly to an integrated transformer suitable for use in switching power supplies with high current output. Background Technology

[0002] Transformers are magnetic core components frequently used in various electrical devices. They utilize the principle of electrical energy to magnetic energy conversion and induction to adjust different voltages to achieve the applicable range for electrical equipment. Common power supplies require multiple transformers, which negatively impacts PCB layout, space occupation, and power density. Furthermore, some transformers have complex structures, are difficult to wind, and are cumbersome to manufacture, which is highly detrimental to efficient production in enterprises.

[0003] Therefore, it is necessary to provide an integrated transformer suitable for high-current output switching power supplies, which has a simple structure, high quality, and greatly reduces the labor intensity of workers. Summary of the Invention

[0004] This invention discloses an integrated transformer suitable for high-current output switching power supplies, which aims to solve the problem of high power density requirements of power supplies and can effectively solve the technical problems involved in the background art.

[0005] To achieve the above objectives, the technical solution of the present invention is as follows:

[0006] An integrated transformer suitable for high-current output switching power supplies includes an upper magnetic core assembly, a lower magnetic core assembly, a peripheral magnetic core assembly, and a copper sheet coil assembly. The lower magnetic core assembly is connected to the bottom of the upper magnetic core assembly. An inner mounting cavity is formed between the upper and lower magnetic core assemblies. The upper magnetic core assembly has an upper central column in the inner mounting cavity, and the lower magnetic core assembly has a lower central column in the inner mounting cavity. The upper and lower central columns are positioned correspondingly and abut against each other to form a mounting post. The peripheral magnetic core assembly is connected to the bottom of the lower magnetic core assembly. An outer mounting cavity is formed between the peripheral and lower magnetic core assemblies. An outer central column is formed within the outer mounting cavity of the peripheral magnetic core assembly. The copper sheet coil assembly includes a copper sheet portion, a primary coil, and a peripheral coil. The copper sheet portion and the primary coil are multiple in number and are arranged alternately on the mounting post. The peripheral coil is disposed on the outer central column, and the primary coil and the peripheral coil are connected in series.

[0007] This invention relates to the field of transformer structure technology and provides a transformer structure suitable for high-current output switching power supplies. It includes three magnetic core groups, a winding bushing on the central column of the main magnetic core group, and the exterior of the winding bushing for placing primary winding coils and copper busbars on the central column of the main magnetic core group. Wire coils are placed between the busbars, and insulating tape is applied between the coils. The wire coils on the main magnetic core group are connected in series with those on the auxiliary magnetic core group. This effectively avoids the difficulties, high labor costs, and material costs associated with using thicker multi-strand stranded wires for winding, and also integrates the transformer with the external inductor, reducing the required space.

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

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

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

[0011] As a preferred improvement of the present invention, an insulation 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 one and a copper sheet group two, the copper sheet group one and the copper sheet group two have the same structure, but their lead directions are opposite.

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

[0014] As a preferred improvement of the present invention, insulating elements are provided on both the upper and lower sides of the bus copper sheet.

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

[0016] As a preferred improvement of the present invention: the copper sheet coil assembly further includes an elastic insulating limiting ring, which is sleeved on the mounting post and used to press the copper sheet portion and the primary coil.

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

[0018] This invention can meet the requirements of low voltage and high current without wasting labor and materials due to winding difficulties, thereby improving production efficiency. It also allows the transformer and external inductor to be integrated, reducing the burden of high power density requirements and greatly improving the utilization rate of the secondary winding. Furthermore, by increasing or decreasing the number and thickness of the secondary winding copper sheets, it can meet the requirements of different output currents, making the operation flexible and effectively avoiding problems such as material confusion and procurement difficulties. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. 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 effort, wherein:

[0020] Figure 1 This is a schematic diagram of an integrated transformer suitable for high current output switching power supplies according to the present invention.

[0021] Figure 2 This is an exploded view of the transformer of the present invention;

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

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

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

[0025] Figure 6 This is an exploded view of the copper sheet assembly of the present invention;

[0026] Figure 7 This is a schematic diagram of the pie chart structure of the present invention.

[0027] In the diagram: 100 - Upper magnetic core assembly, 110 - Upper middle column, 200 - Lower magnetic core assembly, 210 - Lower middle column, 300 - Outer magnetic core assembly, 310 - Outer middle column, 400 - Copper sheet coil assembly, 410 - Copper sheet section, 411 - Copper sheet group one, 4111 - Busbar copper sheet, 4112 - Lead one, 4113 - Lead one, 4114 - Insulating component, 412 - Copper sheet group two, 420 - Primary coil, 430 - Outer coil, 500 - Positioning plate, 600 - Fixing component. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

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

[0030] Furthermore, in this invention, descriptions involving "first," "second," etc., are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0031] In this invention, unless otherwise explicitly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0032] Furthermore, the technical solutions of the various embodiments of the present invention can be combined with each other, but only if they are feasible for those skilled in the art. If the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by the present invention.

[0033] Please see Figures 1-3 As shown, this invention provides an integrated transformer suitable for high-current output switching power supplies, including an upper magnetic core assembly 100, a lower magnetic core assembly 200, a peripheral magnetic core assembly 300, and a copper sheet coil assembly 400. The lower magnetic core assembly 200 is connected to the bottom of the upper magnetic core assembly 100. An inner mounting cavity is formed between the upper magnetic core assembly 100 and the lower magnetic core assembly 200. The upper magnetic core assembly 100 has an upper central column 110 within the inner mounting cavity, and the lower magnetic core assembly 200 has a lower central column 210 within the inner mounting cavity. The upper central column 110 and the lower central column 210 are positioned correspondingly and abut against each other to form a mounting post. The peripheral magnetic core assembly 300 is connected to the bottom of the lower magnetic core assembly 200. A peripheral mounting cavity is formed between the peripheral magnetic core assembly 300 and the lower magnetic core assembly 200. The peripheral magnetic core assembly 300 has a peripheral central post 310 within the peripheral mounting cavity. The copper sheet / coil assembly 400 includes a copper sheet portion 410, a primary coil 420, and a peripheral coil 430. Multiple copper sheet portions 410 and primary coils 420 are arranged alternately on the mounting post. The peripheral coil 430 is positioned on the peripheral central post 310, and the primary coil 420 and peripheral coil 430 are connected in series. Multiple copper sheet / coil assemblies 400 are included (three in this embodiment). The upper magnetic core assembly 100 has the same number of upper central posts 110 as the copper sheet / coil assemblies 400. The number of lower central posts 210 and peripheral central posts 310 is the same as the number of upper central posts 110, and they are arranged correspondingly in sequence.

[0034] Please see Figures 4-7 As shown, an insulation mechanism, such as an insulating plate or similar structure, is provided between the copper sheet portion 410 and the primary coil 420. The copper sheet portion 410 includes a first copper sheet group 411 and a second copper sheet group 412. The first copper sheet group 411 and the second copper sheet group 412 have the same structure, but their lead directions are opposite. The copper sheet group 411 includes two identical busbar copper sheets 4111. The busbar copper sheet 4111 is annular and has a notch. At the notch, the two ends of the busbar copper sheet 4111 are respectively provided with a first lead 4112 and a second lead 4113. One busbar copper sheet 4111 is flipped 180° and stacked on top of the other busbar copper sheet 4111 to form the copper sheet group 411. The first lead 4112 of the upper busbar copper sheet 4111 is directly above the first lead 4112 of the lower busbar copper sheet 4111. Insulating members 4114 are provided on both the upper and lower sides of the busbar copper sheet 4111.

[0035] Specifically, the transformer includes two equidistant core groups, one peripheral inductor core group, equidistantly arranged core group columns, external busbars, and integrally wound primary coils and peripheral coils. The external area of ​​the core group column can be used to place the primary coil, which is composed of multiple coils connected in series. Insulating tape is added between the coil and the busbar. After multiple primary coils are connected in series on the two equidistant core groups, they are then connected in series with the peripheral coils placed on the external area of ​​the peripheral inductor core group column. Two busbars are stacked after being flipped 180° in planar rotation, with insulating tape between them. The two stacked busbars after being flipped 180° in planar rotation are then stacked with two other stacked busbars rotated 180° horizontally, with opposite lead directions. The winding area outside the equidistant core group column can also be wound using single coils connected in parallel. The outer side of the equidistant core assembly's central column is used to place stacked busbar copper sheets. These busbar copper sheets are arranged in four different directions, with insulating tape between each sheet. The outer side of the equidistant core assembly's central column can also be used to place primary coils, which are formed by connecting coils in series. These primary coils placed on the outer side of the equidistant core assembly's central column are then connected in series with the coils placed on the outer core assembly's central column.

[0036] In one implementation, the upper magnetic core assembly 100, the lower magnetic core assembly 200, and the peripheral magnetic core assembly 300 are connected by adhesive. The transformer also includes a fixing member 600, which is sleeved around the upper magnetic core assembly 100, the lower magnetic core assembly 200, and the peripheral magnetic core assembly 300, and is used to fix the former three. The transformer also includes a positioning plate 500, which has multiple positioning holes. The positioning holes are set corresponding to the positions of the first output pin 4112 and the second output pin 4113, which facilitates the stabilization of the busbar copper sheets and avoids contact between the busbar copper sheets. The copper sheet coil assembly 400 also includes an elastic insulating limiting ring, which is sleeved on the mounting post and is used to press the copper sheet part 410 and the primary coil 420. When the number of coils and copper sheets sleeved on the central post is small, the coils and copper sheets may be relatively loose and easy to slide. The elastic insulating limiting ring prevents them from moving. It should be further noted that any other components used to achieve the above effects should fall within the inventive concept of this invention and should be protected within the scope of this invention.

[0037] Example 1

[0038] This embodiment provides a transformer structure suitable for high-current output switching power supplies, including two equidistant magnetic core groups (100 and 200 in the figure), an outer inductor core group (300 in the figure), busbars on the outside of the equidistant core group columns, and an integrated wound coil. The outside of the equidistant core group columns is used to place the primary coil, which is composed of multiple coils connected in series. The outside of the equidistant core group columns is used to place the busbars. First, one busbar is placed on the equidistant core group column. Then, the second busbar is rotated 180° and placed on the same column. Each busbar is separated by insulating tape. At this point, the leads of the two busbars are in the same direction. These two busbars are defined as a group. Then, another group of busbars is rotated 180° horizontally and placed on the same column. At this point, the leads of the two groups of busbars are not in the same direction. Next, place a portion of the primary coil, then two sets of bus plates, and then another portion of the primary coil, repeating this cycle. Finally, after placing the primary coil and bus plates on the equidistant core assembly, a portion of the primary coil is placed onto the central post of the outer inductor core assembly. The winding area outside the central post of the equidistant core assembly can also be wound using multiple wires connected in parallel, and the winding on the outer inductor core assembly can also be made using multiple wires connected in parallel, which are then connected in series with the coils on the central post of the equidistant core assembly. However, attention must be paid to the winding direction of each coil.

[0039] Although embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for the present invention. Other modifications can be easily made by those skilled in the art. Therefore, without departing from the general concept defined by the claims and their 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 high-current output switching power supplies, characterized in that: The assembly includes an upper magnetic core assembly (100), a lower magnetic core assembly (200), a peripheral magnetic core assembly (300), and a copper sheet wire assembly (400). The lower magnetic core assembly (200) is connected to the bottom of the upper magnetic core assembly (100). An inner mounting cavity is formed between the upper magnetic core assembly (100) and the lower magnetic core assembly (200). The upper magnetic core assembly (100) has an upper central post (110) within the inner mounting cavity, and the lower magnetic core assembly (200) has a lower central post (210) within the inner mounting cavity. The upper central post (110) and the lower central post (210) are positioned correspondingly and abut against each other to form a mounting post. The peripheral magnetic core assembly (300) is connected to the lower magnetic core assembly (400). At the bottom of the magnetic core assembly (200), an outer mounting cavity is enclosed between the outer magnetic core assembly (300) and the lower magnetic core assembly (200). The outer magnetic core assembly (300) has an outer central column (310) in the outer mounting cavity. The copper sheet wire assembly (400) includes a copper sheet part (410), a primary wire cake (420) and an outer wire cake (430). There are multiple copper sheet parts (410) and primary wire cakes (420), which are arranged alternately on the mounting column. The outer wire cake (430) is arranged on the outer central column (310). The primary wire cake (420) and the outer wire cake (430) are connected in series. The number of copper sheet wire assembly (400) is multiple. The upper magnetic core group (100) is provided with the same number of upper central columns (110) as the number of copper sheet wire assembly (400). The number of lower central columns (210) and peripheral central columns (310) is the same as the number of upper central columns (110), and they are arranged in sequence. The copper sheet section (410) includes a copper sheet group one (411) and a copper sheet group two (412). The copper sheet group one (411) and the copper sheet group two (412) have the same structure, but their lead directions are opposite. The copper sheet group one (411) includes two identical busbar copper sheets (4111). The busbar copper sheet (4111) is annular and has a notch. At the notch, the two ends of the busbar copper sheet (4111) are respectively provided with a first protrusion (4112) and a second protrusion (4113). One of the busbar copper sheets (4111) is flipped 180° and stacked on top of the other busbar copper sheet (4111) to form the copper sheet group one (411). The first protrusion (4112) of the upper busbar copper sheet (4111) is directly above the first protrusion (4112) of the lower busbar copper sheet (4111). The transformer also includes a positioning plate (500), which has multiple positioning holes, and the positioning holes are set to correspond to the positions of the first output (4112) and the second output (4113).

2. The integrated transformer for high-current output switching power supplies according to claim 1, characterized in that: The upper magnetic core assembly (100), the lower magnetic core assembly (200), and the peripheral magnetic core assembly (300) are connected by adhesive.

3. The integrated transformer for high-current output switching power supplies according to claim 1, characterized in that: The transformer also includes a fixing component (600), which is fixedly sleeved around the upper magnetic core group (100), the lower magnetic core group (200) and the outer magnetic core group (300).

4. An integrated transformer suitable for high-current output switching power supplies according to claim 1, characterized in that: An insulation mechanism is provided between the copper sheet portion (410) and the primary wire disc (420).

5. An integrated transformer suitable for high-current output switching power supplies according to claim 1, characterized in that: The busbar copper sheet (4111) is provided with insulating parts (4114) on both the upper and lower sides.

6. An integrated transformer suitable for high-current output switching power supplies according to claim 1, characterized in that: The copper sheet coil assembly (400) further includes an elastic insulating limiting ring, which is sleeved on the mounting post and used to press the copper sheet portion (410) and the primary coil (420).

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