Stacked coil transformer structure

Abstract

The invention relates to the technical field of transformers, in particular to a stacked coil transformer structure which comprises an iron core assembly and a coil assembly. The iron core assembly provides a low-magnetic-resistance path, magnetic resistance and magnetic leakage are reduced, the magnetic field intensity and the magnetic energy utilization rate are improved, and the voltage and current conversion efficiency is improved. The coil assembly comprises two primary coils and a secondary coil; the two primary coils are respectively wound on the iron core assembly; the secondary coil is also wound on the iron core assembly and located between the two primary coils. Compared with a traditional transformer, the primary coil and the secondary coil are ingeniously stacked, and higher power density is achieved in a small space. By optimizing the path of the alternating current, the eddy current loss is reduced, the energy loss is reduced, and the conversion efficiency is improved. The device is especially suitable for high-frequency alternating current. And the generated magnetic field is relatively uniform, can be accurately controlled, and is suitable for the fields of magnetic resonance imaging, particle accelerators and the like.

Description

Technical Field

[0001] The present invention relates to the technical field of transformers, and in particular to a stacked coil transformer structure. Background Art

[0002] A transformer is a device that uses the principle of electromagnetic induction to change AC voltage. The main components of a traditional transformer are the primary coil, the secondary coil and the iron core, which have functions such as voltage conversion, current conversion, impedance conversion, isolation and voltage stabilization.

[0003] With the development of technology, how to achieve higher power density in a smaller space has become a technical problem that needs to be solved urgently by technicians in this field. Summary of the invention

[0004] The present invention provides a stacked coil transformer structure to solve the problem of how to achieve higher power density in a smaller space.

[0005] The present invention provides a stacked coil transformer structure, comprising: Core assembly; The coil assembly comprises two primary coils and a secondary coil; the two primary coils are respectively wound on the iron core assembly; the secondary coil is wound on the iron core assembly and is located between the two primary coils; There are multiple coil assemblies; the free ends of the primary coils of the multiple coil assemblies are connected in parallel, the free ends of the other primary coils are connected in parallel, and the secondary coils are connected in series in sequence.

[0006] In some embodiments, a conductor is wound multiple layers from outside to inside in a first plane to form one of the primary coils, and multiple layers are wound from inside to outside in a second plane to form another primary coil; The secondary coil is a conductive sheet; the plane where the conductive sheet is located is located between the first plane and the second plane.

[0007] In some of the embodiments, an insulating sheet is disposed between the conductive sheet and each primary coil.

[0008] In some embodiments, it also includes: The retractable wire assembly is installed on the core assembly and is used to adjust the number of winding layers of the primary coil located in the second plane.

[0009] In some of the embodiments, the core assembly is a closed ring structure.

[0010] In some of the embodiments, the core assembly includes a first magnetic conductive segment, a second magnetic conductive segment, a third magnetic conductive segment, and a fourth magnetic conductive segment which are detachably connected end to end in sequence.

[0011] In some embodiments, the materials of the first magnetic conductive segment, the second magnetic conductive segment, the third magnetic conductive segment and the fourth magnetic conductive segment are the same or different.

[0012] In some embodiments, it also includes: The magnetic isolation component is movably arranged at the connection of the magnetic conductive sections.

[0013] In some embodiments, it also includes: The heat dissipation component is arranged between the coil component and the iron core component.

[0014] The beneficial effects of the present invention are as follows: The stacked coil transformer structure of the present invention is provided with an iron core component and a coil component, and the iron core component provides a low magnetic resistance path, so that the magnetic flux can pass smoothly, reduce magnetic resistance and leakage magnetic flux, improve the magnetic field strength and magnetic energy utilization rate, and improve the voltage and current conversion efficiency. At the same time, the coil component is effectively supported to ensure the stability of the position of the coil component. In addition, the iron core component can assist the stacked coil transformer structure in heat dissipation to prevent the stacked coil transformer structure from overheating. Compared with the traditional transformer, the primary coil and the secondary coil are cleverly stacked to achieve a higher power density in a smaller space. By optimizing the path of the alternating current, the eddy current loss is reduced, the energy loss is reduced, and the conversion efficiency is improved. It is particularly suitable for high-frequency alternating current. The generated magnetic field is also relatively uniform, and the magnetic field can be accurately controlled, which is suitable for magnetic resonance imaging and particle accelerators. In addition, the overall structure of the coil component is relatively simple, easy to manufacture, saving production costs, improving production efficiency, and is conducive to rapid heat dissipation, ensuring stable operation of the transformer under high load. When subjected to external shock or vibration, good structural stability is maintained. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a structural schematic diagram of some specific embodiments of a stacked coil transformer structure of the present invention; Figure 2 yes Figure 1 A schematic diagram of the structure of the coil assembly in the stacked coil transformer structure shown; Figure 3 yes Figure 2 A top view of one of the primary coils of the coil assembly shown; Figure 4 yes Figure 2 A top view of the secondary coil of the coil assembly shown; Figure 5 yes Figure 2 A top view of another primary coil of the coil assembly shown; Figure 6 It is a schematic diagram of the electrical connection of the primary coil of the coil assembly; Figure 7It is a schematic diagram of the electrical connection of the secondary coil of the coil assembly; Figure 8 It is a schematic structural diagram of some other specific embodiments of a stacked coil transformer structure of the present invention; Fig. 9 It is a structural schematic diagram of some specific embodiments of a stacked coil transformer structure of the present invention; Fig.10 yes Fig. 9 A cross-sectional view of a heat sink in a stacked coil transformer structure is shown; Fig.11 It is a structural schematic diagram of some specific embodiments of a stacked coil transformer structure of the present invention; Fig.12 yes Fig.11 A top view of the retractable wire assembly in the stacked coil transformer structure is shown.

[0016] In the accompanying drawings, 110, core assembly; 111, first magnetic conductive section; 112, second magnetic conductive section; 113, third magnetic conductive section; 114, fourth magnetic conductive section; 120, coil assembly; 121, primary coil; 122, secondary coil; 123, insulating sheet; 130, magnetic isolation assembly; 140, heat dissipation assembly; 141, heat dissipation bushing; 1411, coolant flow cavity; 142, coolant inflow pipe; 143, coolant outflow pipe; 150, retractable wire assembly; 151, upper track; 152, lower track; 153, upper slider; 154, lower slider; 155, transmission rod; 156, winding wheel; 157, limit ring. DETAILED DESCRIPTION

[0017] The technical solution of the present invention will be clearly and completely described below in conjunction with the embodiments. Obviously, the described embodiments are part of the embodiments of the present invention, rather than 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.

[0018] As described in the background art, how to achieve higher power density in a smaller space has become a technical problem that needs to be solved urgently by those skilled in the art.

[0019] To solve the above problems, refer to Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 , Figure 8 , Fig. 9 , Fig.10 , Fig.11 and Fig.12The present invention provides a stacked coil transformer structure, including a core assembly 110 and a coil assembly 120. The core assembly 110 provides a low magnetic resistance path, so that the magnetic flux can pass smoothly, reducing magnetic resistance and leakage magnetic flux, improving the magnetic field strength and magnetic energy utilization, and improving the voltage and current conversion efficiency. At the same time, the coil assembly 120 is effectively supported to ensure the stability of the position of the coil assembly 120. In addition, the core assembly 110 can assist the stacked coil transformer structure in heat dissipation to prevent the stacked coil transformer structure from overheating. The coil assembly 120 includes two primary coils 121 and a secondary coil 122. The two primary coils 121 are respectively wound on the core assembly 110. The secondary coil 122 is also wound on the core assembly 110 and is located between the two primary coils 121. Compared with traditional transformers, the primary coil 121 and the secondary coil 122 are cleverly stacked to achieve higher power density in a smaller space. By optimizing the path of the alternating current, the eddy current loss is reduced, the energy loss is reduced, and the conversion efficiency is improved. It is particularly suitable for high-frequency alternating current. The generated magnetic field is also relatively uniform, and the magnetic field can be precisely controlled, which is applicable to the fields of magnetic resonance imaging and particle accelerators. In addition, the overall structure of the coil assembly 120 is relatively simple and easy to manufacture, which saves production costs, improves production efficiency, and is conducive to rapid heat dissipation, ensuring stable operation of the transformer under high load. When subjected to external shock or vibration, it maintains good structural stability.

[0020] Specifically, in the example, Figure 1 , Figure 2 , Figure 3 , Figure 4 and Figure 5 As shown, a conductor is first wound in multiple layers from outside to inside in a first plane to form one of the primary coils 121 ( Figure 3 The direction of the arrow in the middle is the winding direction), and then the wire is wound in multiple layers from the inside to the outside in the second plane to form another primary coil 121 ( Figure 5 The arrow direction is the winding direction). The secondary coil 122 is a conductive sheet. It should be noted that the plane where the conductive sheet is located is located between the first plane and the second plane. In this way, the power density can be further improved in a smaller space. At the same time, a suitable inductance is obtained.

[0021] Preferably, the material of the wire wound around the primary coil 121 is a material with excellent conductivity, such as copper, aluminum, silver or gold.

[0022] Preferably, the conductive sheet is a non-closed ring structure, provided with a first electrical connection end and a second electrical connection end. The conductive sheet is made of a material with excellent electrical conductivity such as copper, aluminum, silver or gold.

[0023] Preferably, an insulating sheet 123 is provided between the conductive sheet and each primary coil 121 , respectively, so as to isolate the conductive sheet from each primary coil 121 .

[0024] Preferably, the insulating sheet 123 is phenolic paperboard, epoxy board, cardboard, polyester film, telephone paper or composite paper.

[0025] Preferably, the conductive sheet is coaxially arranged with each primary coil 121 to optimize the magnetic field distribution.

[0026] Specifically, in the example, Figure 1 , there are multiple coil assemblies 120. The coil assemblies 120 can be one, two, three, four, five, six, seven or eight to obtain different voltage / current conversion rates. Figure 6 As shown, the free ends of one primary coil 121 of the plurality of coil assemblies 120 are connected in parallel, and the free ends of the other primary coils 121 are connected in parallel, so as to ensure that the input voltage of each primary coil 121 of each coil assembly 120 is consistent. Figure 7 As shown, the secondary coils 122 of each coil assembly 120 are connected in series in sequence through wires, and the output voltage / current is the superimposed voltage / current.

[0027] Specifically, in the example, Figure 1 As shown, the core assembly 110 is a closed ring structure to form a complete magnetic circuit.

[0028] Preferably, the core assembly 110 is a square ring structure, a circular ring structure, a triangle structure or a racetrack structure.

[0029] Preferably, the core assembly 110 is a square ring structure, including a first magnetic conductive segment 111, a second magnetic conductive segment 112, a third magnetic conductive segment 113 and a fourth magnetic conductive segment 114 which are detachably connected end to end, so as to facilitate the disassembly, replacement and assembly of the stacked coil transformer structure. A plurality of coil assemblies 120 are respectively wound on the first magnetic conductive segment 111 and the third magnetic conductive segment 113, while no coil assemblies 120 are wound on the second magnetic conductive segment 112 and the fourth magnetic conductive segment 114. This facilitates subsequent processing and prevents unbalanced weight.

[0030] Preferably, the first magnetic conductive segment 111 , the second magnetic conductive segment 112 , the third magnetic conductive segment 113 and the fourth magnetic conductive segment 114 can be detachably connected by screwing, clamping or bonding.

[0031] In some embodiments, the first magnetic conductive segment 111 , the second magnetic conductive segment 112 , the third magnetic conductive segment 113 , and the fourth magnetic conductive segment 114 are made of the same material.

[0032] In other embodiments, the materials of the first magnetic conductive segment 111, the second magnetic conductive segment 112, the third magnetic conductive segment 113 and the fourth magnetic conductive segment 114 are different from each other. For example, the material of the first magnetic conductive segment 111 is silicon steel, the material of the second magnetic conductive segment 112 is amorphous alloy, the material of the third magnetic conductive segment 113 is nanocrystalline alloy, and the material of the fourth magnetic conductive segment 114 is ferrite, beryllium-molybdenum alloy, cold-rolled silicon steel sheet or electrical steel. In this way, the appropriate magnetic permeability and hysteresis loss can be adjusted according to needs.

[0033] Preferably, the cross-sections of the first magnetic conductive segment 111 , the second magnetic conductive segment 112 , the third magnetic conductive segment 113 and the fourth magnetic conductive segment 114 are rectangular.

[0034] Preferably, the first magnetic conductive segment 111 and the third magnetic conductive segment 113 have the same length, and the second magnetic conductive segment 112 and the fourth magnetic conductive segment 114 have the same length. In addition, the second magnetic conductive segment 112 is shorter than the first magnetic conductive segment 111 .

[0035] In other applications, such as Figure 8 As shown, the stacked coil transformer structure further includes a magnetic isolation component 130. The magnetic isolation component 130 includes four magnetic isolation plates. The four magnetic isolation plates are movably disposed at the connection of the four magnetic conductive sections. It should be noted that, Figure 8 The direction of the arrow in the middle is the direction of movement of the magnetic isolation sheet. By precisely adjusting the depth of each magnetic isolation sheet inserted into the connection, the magnetic resistance can be precisely increased and the magnetic flux can be reduced, thereby precisely controlling the efficiency of the transformer.

[0036] In some other applications, such as Fig. 9 and Fig.10 As shown, the stacked coil transformer structure also includes a heat dissipation component 140. The heat dissipation component 140 is arranged between the coil assembly 120 and the core assembly 110, and is used to dissipate heat for the stacked coil transformer structure, so as to ensure that the high-frequency transformer operates stably under high load. The heat dissipation component 140 includes two heat dissipation bushings 141, two coolant inflow pipes 142 and two coolant outflow pipes 143. A coolant flow cavity 1411 is formed inside the side wall of each heat dissipation bushing 141. One of the heat dissipation bushings 141 is arranged between the first magnetic conductive section 111 and the coil assembly 120. Another heat dissipation bushing 141 is arranged between the third magnetic conductive section 113 and the coil assembly 120. The two coolant inflow pipes 142 are connected to the coolant flow cavity 1411 of the two heat dissipation bushings 141 in a one-to-one correspondence, and are used to supply coolant. The two coolant outflow pipes 143 are connected to the coolant flow cavity 1411 of the two heat dissipation bushings 141 in a one-to-one correspondence, and are used to discharge coolant. Overall, it has a good heat dissipation effect.

[0037] In some other applications, such as Fig.11 and Fig.12As shown, the stacked coil transformer structure also includes a retractable wire assembly 150. The retractable wire assembly 150 is mounted on the core assembly 110, and is used to adjust the number of winding layers of the primary coil 121 located in the second plane. In this way, the power density can be adjusted as needed in a smaller space. Specifically, there are two retractable wire assemblies 150. Each retractable wire assembly 150 includes an upper track 151, a lower track 152, an upper slider 153, a lower slider 154, a transmission rod 155, a plurality of winding wheels 156 and a plurality of limit rings 157. The upper track 151 of one of the retractable wire assemblies 150 is wound around the upper part of the first magnetic conductive section, and the lower track 152 is wound around the lower part of the first magnetic conductive section. The upper track 151 of another retractable wire assembly 150 is wound around the upper part of the third magnetic conductive section, and the lower track 152 is wound around the lower part of the third magnetic conductive section. The upper slider 153 can be slidably installed on the upper track 151 along the upper track 151, and the lower slider 154 can be slidably installed on the lower track 152 along the lower track 152. The axis of the transmission rod 155 is vertically arranged, the bottom end is fixedly connected to the lower slider 154, and the top end is fixedly connected to the upper slider 153. A plurality of winding wheels 156 are arranged in sequence from top to bottom, and are respectively rotatably sleeved on the transmission rod 155 around their own axes. A plurality of limiting rings 157 are arranged in sequence from top to bottom, and are respectively sleeved on the transmission rod 155. Every two limiting rings 157 are respectively located at the top and bottom ends of the same winding wheel 156 to limit the up and down movement of the winding wheel 156. The free end of one of the primary coils of each coil assembly is wound on a winding wheel 156. The same transmission rod 155 rotates around the first magnetic section / third magnetic section to drive each winding wheel 156 to release or reel in the corresponding wire, thereby adjusting the number of winding layers of one of the primary coils of each coil assembly, so that the power density can be adjusted as needed. It should be noted that the retractable wire assembly 150 is made of an insulating and high-temperature resistant material, such as ceramic.

[0038] Specifically, in the exemplary embodiment, the stacked coil transformer structure further includes a housing. The housing is disposed outside the coil assembly 120 and the core assembly 110 to protect the coil assembly 120 and the core assembly 110. At the same time, the coil assembly 120 is isolated from the outside to improve safety.

[0039] In the description of the present invention, it is to be understood that the terms “center”, “longitudinal”, “lateral”, “length”, “width”, “thickness”, “up”, “down”, “front”, “back”, “left”, “right”, “vertical”, “horizontal”, “top”, “bottom”, “inside”, “outside”, “clockwise”, “counterclockwise”, “axial”, “radial”, “circumferential”, etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0040] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "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.

[0041] In the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral one; it can be a mechanical connection, an electrical connection, or communication with each other; 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.

[0042] In the present invention, the terms "one embodiment", "some embodiments", "examples", "specific examples", or "some examples" etc. mean that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the described specific features, structures, materials or characteristics may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine the different embodiments or examples described in this specification and the features of the different embodiments or examples, without contradiction.

[0043] Although the embodiments of the present invention have been shown and described above, it is to be understood that the above embodiments are exemplary and are not to be construed as limitations of the present invention. A person skilled in the art may change, modify, replace and vary the above embodiments within the scope of the present invention.

Claims

1. A stacked coil transformer structure, characterized in that: include: Core assembly; A coil assembly, including two primary coils and a secondary coil; The two primary coils are respectively wound on the core assembly; The secondary coil is wound on the core assembly and located between the two primary coils; There are multiple coil assemblies; the free ends of the primary coils of one of the multiple coil assemblies are connected in parallel, the free ends of the other primary coils are connected in parallel, and the secondary coils are connected in series in sequence.

2. The stacked coil transformer structure according to claim 1, characterized in that: A conductor is wound multiple layers from outside to inside in a first plane to form one of the primary coils, and multiple layers are wound from inside to outside in a second plane to form another primary coil; The secondary coil is a conductive sheet; the plane where the conductive sheet is located is located between the first plane and the second plane.

3. The stacked coil transformer structure according to claim 2, characterized in that: An insulating sheet is respectively arranged between the conductive sheet and each of the primary coils.

4. The stacked coil transformer structure according to claim 2, characterized in that: Also includes: The retractable wire assembly is installed on the core assembly and is used to adjust the number of winding layers of the primary coil located in the second plane.

5. The stacked coil transformer structure according to claim 1, characterized in that: The iron core assembly is a closed ring structure.

6. The stacked coil transformer structure according to claim 5, characterized in that: The core assembly comprises a first magnetic conductive segment, a second magnetic conductive segment, a third magnetic conductive segment and a fourth magnetic conductive segment which are detachably connected end to end in sequence.

7. The stacked coil transformer structure according to claim 6, characterized in that: The materials of the first magnetic conductive segment, the second magnetic conductive segment, the third magnetic conductive segment and the fourth magnetic conductive segment are the same or different.

8. The stacked coil transformer structure according to claim 6, characterized in that: Also includes: The magnetic isolation component is movably arranged at the connection of the magnetic conductive sections.

9. The stacked coil transformer structure according to claim 1, characterized in that: Also includes: The heat dissipation component is arranged between the coil component and the iron core component.

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