An LLC transformer

Abstract

This application provides an LLC transformer, including a magnetic core body, a main transformer winding, and a resonant winding. The magnetic core body is composed of two magnetic cores, which are interlocked to form a closed magnetic circuit. The main transformer winding and the resonant winding are wound on the two magnetic cores. By integrating the main transformer winding and the resonant winding on the same set of magnetic cores, the size of the LLC transformer is reduced, while losses are also reduced.

Description

Technical Field

[0001] This application relates to the field of magnetic device technology, specifically to an LLC transformer. Background Technology

[0002] The LLC transformer is the core component of an LLC resonant converter. It typically contains two inductors (a primary resonant inductor and a secondary resonant inductor) and a transformer body (containing primary and secondary main transformer windings). These components resonate at the switching frequency, thereby achieving efficient power conversion.

[0003] In the LLC topology transformer structure with a split design, the resonant inductor and the main transformer are two completely independent components, and there are many components, so they occupy a lot of extra space. However, the space available for installing transformers is getting smaller and smaller. Therefore, how to reduce the size of transformers is a technical problem that urgently needs to be solved. Summary of the Invention

[0004] In view of this, this application provides an LLC transformer to reduce the size of the device while reducing losses.

[0005] This application provides an LLC transformer, including a magnetic core body, a main transformer winding, and a resonant winding. The magnetic core body is composed of two magnetic cores, which are interlocked to form a closed magnetic circuit. The main transformer winding and the resonant winding are wound on the two magnetic cores.

[0006] In some embodiments, both magnetic cores include a first magnetic side post, a magnetic center post, a second magnetic side post, an isolation post, and a magnetic plate. The first magnetic side post, the magnetic center post, the second magnetic side post, and the isolation post of each magnetic core are all connected to the magnetic plate, and the first magnetic side post, the magnetic center post, the second magnetic side post, and the isolation post of the two magnetic cores are connected in a one-to-one correspondence. The first magnetic side post and the second magnetic side post are located on opposite sides of the magnetic center post. The isolation post is provided between the first magnetic side post and the magnetic center post, and between the magnetic center post and the second magnetic side post. The main transformer winding is wound on the magnetic center post, and the resonant winding is wound on the first magnetic side post and the second magnetic side post.

[0007] In some embodiments, the resonant winding includes a primary resonant winding and a secondary resonant winding, the primary resonant winding being wound on the first magnetic side post and the secondary resonant winding being wound on the second magnetic side post.

[0008] In some embodiments, the main transformer winding includes a primary main transformer winding and a secondary main transformer winding, the primary main transformer winding and the secondary main transformer winding are wound on the magnetic center column, the primary main transformer winding is connected in series with the primary resonant winding, and the secondary resonant winding is connected in series with the secondary resonant winding.

[0009] In some embodiments, the primary transformer winding and the primary resonant winding are wound together using a single conductor, so that the primary transformer winding and the primary resonant winding are connected in series.

[0010] In some embodiments, the secondary main transformer winding and the secondary resonant winding are wound together using a single conductor, so that the secondary main transformer winding and the secondary resonant winding are connected in series.

[0011] In some embodiments, an air gap is provided at the connection between the two magnetic cores.

[0012] In some embodiments, the two magnetic cores are fixedly connected by adhesive dispensing so that the two magnetic cores form a closed magnetic circuit.

[0013] In some embodiments, the LLC transformer further includes a base having an upwardly protruding convex plate forming a fixing groove for fixed connection with one of the two magnetic cores.

[0014] In some embodiments, a fixing hole for fixing a terminal is provided on the outer side of the fixing groove, and the terminal is electrically connected to the main transformer winding and the resonant winding.

[0015] This application provides an LLC transformer, including a magnetic core body, a main transformer winding, and a resonant winding. The magnetic core body is composed of two magnetic cores, which are interlocked to form a closed magnetic circuit. The main transformer winding and the resonant winding are wound on the two magnetic cores. By integrating the main transformer winding and the resonant winding on the same set of magnetic cores, the size of the LLC transformer is reduced, achieving miniaturized device design and reducing losses. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a three-dimensional structural schematic diagram of the LLC transformer provided in this application;

[0018] Figure 2 This is a three-dimensional structural diagram of the magnetic core body provided in this application;

[0019] Figure 3 This is a three-dimensional structural diagram of a magnetic core provided in this application;

[0020] Figure 4 This is a three-dimensional structural diagram of the base provided in this application.

[0021] Figure label:

[0022] 10. LLC transformer; 100. Magnetic core body; 110. Magnetic core; 111. First magnetic side post; 112. Magnetic center post; 113. Second magnetic side post; 114. Isolation post; 115. Magnetic plate; 200. Main transformer winding; 300. Primary resonant winding; 400. Secondary resonant winding; 500. Base; 510. Protruding plate; 520. Fixing slot; 530. Fixing hole. Detailed Implementation

[0023] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application. In the absence of conflict, the following embodiments and their technical features can be combined with each other.

[0024] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying 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 application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified. In the description of this application, "several" means at least one, such as one, two, etc., unless otherwise explicitly specified.

[0025] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of this application. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items. The terms "connection," "electrical connection," and "electrical link" as used herein include any direct and indirect electrical or structural connection means. Therefore, if a first device is described herein as coupled / connected / electrically connected to a second device, it means that the first device can be directly electrically / structurally connected to the second device, or indirectly electrically / structurally connected to the second device through other means or connection methods.

[0026] This application provides an LLC transformer, including a magnetic core body, a main transformer winding, and a resonant winding. The magnetic core body is composed of two magnetic cores, which are interlocked to form a closed magnetic circuit. The main transformer winding and the resonant winding are wound on the two magnetic cores.

[0027] In the prior art, the space available for installing transformers is limited, and transformers with separate designs refer to resonant inductors and main transformers as two completely independent components, which are relatively large and therefore require additional space. In this application, by integrating the main transformer winding and resonant winding onto the same pair of magnetic cores, there is no need to use additional space to place the resonant inductor, thus reducing the size and eliminating the need to fabricate a separate resonant inductor, thereby reducing costs. At the same time, it can reduce losses during energy transmission and improve the overall efficiency of the device.

[0028] Please see Figures 1-4 , Figure 1 This is a three-dimensional structural schematic diagram of the LLC transformer provided in this application; Figure 2 This is a three-dimensional structural diagram of the magnetic core body provided in this application; Figure 3 This is a three-dimensional structural diagram of a magnetic core provided in this application; Figure 4 This is a three-dimensional structural schematic diagram of the base provided in this application. This application provides an LLC transformer. The LLC transformer 10 includes a magnetic core 110 body 100, a main transformer winding 200, and a resonant winding. The magnetic core 110 body 100 is composed of two magnetic cores 110, which are interlocked to form a closed magnetic circuit. The main transformer winding 200 and the resonant winding are wound on the two magnetic cores 110. Specifically, the LLC transformer 10 includes a magnetic core 110 body 100, a main transformer winding 200, and a resonant winding. The magnetic core 110 body 100 is composed of two magnetic cores 110, which are interlocked to form a closed magnetic circuit. The material forming the magnetic core 110 includes at least one of manganese-zinc ferrite, iron-silicon-aluminum, iron-silicon alloy, iron-nickel-molybdenum magnetic powder core, and nickel-zinc ferrite, which is not limited here. The main transformer winding 200 and the resonant winding are wound on the two magnetic cores 110. Both the main transformer winding 200 and the resonant winding are formed by winding wires, which can be Mylar wire or insulated wire, which is not limited here.

[0029] In existing technologies, space for installing transformers is limited, and separate transformer designs, where the resonant inductor and main transformer are two completely independent components, are relatively large and require additional space. In this application, by integrating the main transformer winding 200 and the resonant winding onto the same pair of magnetic cores 110, there is no need to allocate additional space for the resonant inductor, reducing its size. Furthermore, the elimination of the need to fabricate a separate resonant inductor reduces raw material usage and assembly costs, thereby lowering overall costs. Simultaneously, it reduces energy transmission losses and improves the overall efficiency of the device. The material of the magnetic core 110 in this application is not limited, allowing for various material options. 10. The most suitable magnetic core material 110 can be selected according to different application scenarios and needs, so that the product structure can be widely used in a variety of product platforms to meet different market demands. The transformer component of this application is equipped with a resonant inductor magnetic core 110 and a resonant winding, so that the structure of this application is relatively integrated with leakage inductance. It has an actual resonant winding and a resonant inductor magnetic core 110 as a basis, so that the inductance value can be adjusted through the actual resonant winding and the resonant inductor magnetic core 110, resulting in smaller tolerance. Moreover, due to the better stability of the structure, the inductance value is not easy to decay with time and environmental changes. That is, the inductance value is easy to adjust, has small tolerance, and is not easy to decay.

[0030] In one embodiment, both magnetic cores 110 include a first magnetic side post 111, a magnetic center post 112, a second magnetic side post 113, an isolation post 114, and a magnetic plate 115. The first magnetic side post 111, the magnetic center post 112, the second magnetic side post 113, and the isolation post 114 of each magnetic core 110 are all connected to the magnetic plate 115, and the first magnetic side post 111, the magnetic center post 112, the second magnetic side post 113, and the isolation post 114 of the two magnetic cores 110 are connected in a one-to-one correspondence. The first magnetic side post 111 and the second magnetic side post 113 are located on opposite sides of the magnetic center post 112. Isolation posts 114 are provided between the first magnetic side post 111 and the magnetic center post 112, and between the magnetic center post 112 and the second magnetic side post 113. The main transformer winding 200 is wound on the magnetic center post 112, and the resonant winding is wound on the first magnetic side post 111 and the second magnetic side post 113. Specifically, each of the two magnetic cores 110 includes a first magnetic side post 111, a magnetic center post 112, a second magnetic side post 113, an isolation post 114, and a magnetic plate 115. One end of each of the first magnetic side post 111, the magnetic center post 112, the second magnetic side post 113, and the isolation post 114 of each magnetic core 110 is connected to the magnetic plate 115. The first magnetic side post 111, the magnetic center post 112, the second magnetic side post 113, and the isolation post 114 of the two magnetic cores 110 are connected in a one-to-one correspondence. The first magnetic side post 111, the magnetic center post 112, the second magnetic side post 113, and the isolation post 114 are spaced apart. The magnetic plates 115 of the two magnetic cores 110 are arranged opposite each other. The first magnetic side post 111 and the second magnetic side post 113 are located on opposite sides of the magnetic center post 112. Isolation posts 114 are provided between the first magnetic side post 111 and the magnetic center post 112 and between the magnetic center post 112 and the second magnetic side post 113. The main transformer winding 200 is wound on the magnetic center post 112, and the resonant winding is wound on the first magnetic side post 111 and the second magnetic side post 113. That is, the magnetic center post 112 is the magnetic core 110 of the main transformer, and the first magnetic side post 111 and the second magnetic side post 113 are the magnetic core 110 of the resonant inductor. An isolation post 114 is provided between the main transformer winding 200 and the resonant winding to reduce electromagnetic interference between the main transformer winding 200 and the resonant winding, and to disperse and conduct the heat generated in the winding, thereby reducing the operating temperature of the device and improving the device reliability and lifespan. The isolation post 114 can effectively confine the magnetic field inside the corresponding magnetic post, thereby reducing magnetic field leakage and energy loss, and thus enabling the circuit to transfer electrical energy more efficiently, improving the overall efficiency of the system.

[0031] In one embodiment, the resonant winding includes a primary resonant winding 300 and a secondary resonant winding 400. The primary resonant winding 300 is wound on the first magnetic side post 111, and the secondary resonant winding 400 is wound on the second magnetic side post 113. Specifically, the resonant winding includes a primary resonant winding 300 and a secondary resonant winding 400. The primary resonant winding 300 is wound on the first magnetic side post 111 of the two magnetic cores 110, and the primary resonant winding 300 is wound on the second magnetic side post 113 of the two magnetic cores 110. In this application, by winding the resonant winding of the resonant inductor on the magnetic side posts on both sides of the main transformer winding 200, the winding space is increased, making the winding process easier and more flexible, and also helping to achieve a flattened design of the device, further reducing the size of the device in the height direction.

[0032] In one embodiment, the main transformer winding 200 includes a primary main transformer winding and a secondary main transformer winding. The primary main transformer winding and the secondary main transformer winding are wound on the magnetic center column 112, that is, the primary main transformer winding and the secondary main transformer winding are wound on the same magnetic column. The primary main transformer winding is connected in series with the primary resonant winding 300, and the secondary resonant winding 400 is connected in series with the secondary resonant winding 400. In this application, by winding the primary transformer winding and the secondary transformer winding on the same magnetic column, magnetic flux can be shared more effectively, thereby reducing leakage flux and improving the energy conversion efficiency of the transformer. This also enhances the electromagnetic coupling between them, reduces the amount of core material required, and simplifies the winding layout and connection, thus simplifying the transformer structure and reducing manufacturing costs. Furthermore, by setting the secondary transformer winding in series with the secondary resonant winding 400, and by setting the secondary transformer winding and the secondary resonant winding 400 in series, the power conversion efficiency, energy transmission and conversion are improved, circuit performance is optimized, and circuit stability and safety are enhanced.

[0033] In one embodiment, the primary transformer winding and the primary resonant winding 300 are wound integrally with a single conductor, so that the primary transformer winding and the primary resonant winding 300 are connected in series, that is, the primary transformer winding and the primary resonant winding 300 are formed by winding with a single conductor. By forming the primary transformer winding and the primary resonant winding 300 with a single conductor, the number of winding components that need to be manufactured separately is reduced, thereby simplifying the assembly structure of the transformer. By forming the primary transformer winding and the primary resonant winding 300 with a single conductor, the two windings can be directly connected through the conductor itself without additional welding or connectors, which simplifies the connection process and reduces welding points, thereby reducing welding costs. Reducing the number of welding points can reduce the failure rate caused by poor welding and improve the reliability of the device. Using a single conductor to wind the two windings makes the winding process more suitable for automated production, thereby completing the winding work efficiently and improving production efficiency.

[0034] In one embodiment, the secondary main transformer winding and the secondary resonant winding 400 are wound together using a single conductor, so that the secondary main transformer winding and the secondary resonant winding 400 are connected in series, that is, the secondary main transformer winding and the secondary resonant winding 400 are formed by winding with a single conductor. By using a single conductor to form the secondary main transformer winding and the secondary resonant winding 400, the number of winding components that need to be manufactured separately is reduced, thereby simplifying the assembly structure of the transformer. By using a single conductor to form the secondary main transformer winding and the secondary resonant winding 400, the two windings can be directly connected through the conductor itself without additional welding or connectors, which simplifies the connection process and reduces welding points, thereby reducing welding costs. Reducing the number of welding points can reduce the failure rate caused by poor welding and improve the reliability of the device. Using a single conductor to wind the two windings makes the winding process more suitable for automated production, thereby completing the winding work efficiently and improving production efficiency.

[0035] In one embodiment, an air gap is provided at the connection point of the two magnetic cores 110. Specifically, when the first magnetic side post 111, magnetic center post 112, second magnetic side post 113, and isolation post 114 of one magnetic core 110 are connected one-to-one with the first magnetic side post 111, magnetic center post 112, second magnetic side post 113, and isolation post 114 of the other magnetic core 110, air gaps are provided between the two first magnetic side posts 111, the two magnetic center posts 112, the two second magnetic side posts 113, and the two isolation posts 114. The air gap can be air or an air gap sheet formed of a non-magnetic material. The air gap at the connection point of the two magnetic cores 110 allows the inductance of the magnetic circuit to be adjusted through the air gap, ensuring the frequency response and stability of the circuit. Further, the air gap is an air gap sheet formed of a non-magnetic material, and the air gap sheet is connected to the two magnetic cores 110 through a colloid.

[0036] In one embodiment, the two magnetic cores 110 are fixedly connected by adhesive dispensing, that is, the two magnetic cores 110 are fixedly connected by adhesive to form a closed magnetic circuit, thereby improving mechanical stability and preventing the two magnetic cores 110 from moving due to vibration or temperature changes, thus maintaining the stability and reliability of the magnetic circuit, reducing magnetic leakage, and improving the efficiency and performance of the magnetic circuit.

[0037] In one embodiment, the LLC transformer 10 further includes a base 500, on which an upwardly protruding plate 510 is provided. The plate 510 forms a fixing groove 520 for fixed connection with one of the two magnetic cores 110. The base 500 can fix the relative positions of the components of the device, facilitating installation onto a PCB board.

[0038] In one embodiment, a fixing hole 530 for fixing terminals is provided on the outer side of the fixing slot 520. The terminals are electrically connected to the main transformer winding 200 and the resonant winding. By providing the fixing hole 530 for fixing terminals on the base 500, the wire ends of the windings are prevented from loosening or falling off due to vibration during motor operation, thereby avoiding electrical or mechanical failures caused by such failures and ensuring the reliability of the device.

[0039] In one embodiment, the LLC transformer 10 further includes a frame, which is fitted onto the first magnetic side post 111, the second magnetic side post 113 and the magnetic center post 112 to fix the position of the winding and prevent it from deforming or shifting during the operation of the device, thereby ensuring the reliability and service life of the device.

[0040] In one embodiment, the diameter of the magnetic center post 112 is larger than the diameters of the first magnetic side post 111 and the second magnetic side post 113, so that the magnetic center post 112 can provide a larger magnetic flux area, thereby allowing a larger current to pass through to meet the needs of high power transmission, and reducing the magnetic flux density, reducing the saturation risk of the magnetic core 110, ensuring that the transformer can operate stably over a wide input voltage range. At the same time, it provides a larger heat dissipation area, which helps to dissipate heat and reduce temperature rise, thereby improving the reliability and service life of the transformer. The smaller diameters of the first magnetic side post 111 and the second magnetic side post 113 make it easier to control the self-inductance coefficient (inductance value) of the resonant inductor and help to optimize the frequency response and stability of the resonant circuit.

[0041] The above description is merely an embodiment of this application and does not limit the patent scope of this application. Any equivalent structural or procedural transformations made using the content of this application's specification and drawings, such as the combination of technical features between embodiments, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this application.

Claims

1. An LLC transformer, characterized in that, It includes a magnetic core body, a main transformer winding, and a resonant winding. The magnetic core body is composed of two magnetic cores, which are interlocked to form a closed magnetic circuit. The main transformer winding and the resonant winding are wound on the two magnetic cores. Both magnetic cores include a first magnetic side post, a magnetic center post, a second magnetic side post, an isolation post, and a magnetic plate. The first magnetic side post, the magnetic center post, the second magnetic side post, and the isolation post of each magnetic core are all connected to the magnetic plate. The first magnetic side post, the magnetic center post, the second magnetic side post, and the isolation post of the two magnetic cores are connected in a one-to-one correspondence. The first magnetic side post and the second magnetic side post are located on opposite sides of the magnetic center post. The isolation post is provided between the first magnetic side post and the magnetic center post, and between the magnetic center post and the second magnetic side post. The main transformer winding is wound on the magnetic center post, and the resonant winding is wound on the first magnetic side post and the second magnetic side post. The resonant winding includes a primary resonant winding and a secondary resonant winding. The primary resonant winding is wound on the first magnetic side post, and the secondary resonant winding is wound on the second magnetic side post. The main transformer winding includes a primary main transformer winding and a secondary main transformer winding, which are wound on the magnetic center column. The primary main transformer winding and the primary resonant winding are wound together using a single conductor, and the secondary main transformer winding and the secondary resonant winding are wound together using a single conductor. Furthermore, the diameter of the magnetic center post is greater than the diameters of the first magnetic side post and the second magnetic side post.

2. The LLC transformer according to claim 1, characterized in that, The primary main transformer winding is connected in series with the primary resonant winding, and the secondary resonant winding is connected in series with the secondary resonant winding.

3. The LLC transformer according to claim 1, characterized in that, An air gap is provided at the connection point of the two magnetic cores.

4. The LLC transformer according to claim 1, characterized in that, The two magnetic cores are fixedly connected by adhesive dispensing so that the two magnetic cores form a closed magnetic circuit.

5. The LLC transformer according to claim 1, characterized in that, The LLC transformer also includes a base with an upwardly protruding plate forming a fixing groove for fixed connection with one of the two magnetic cores.

6. The LLC transformer according to claim 5, characterized in that, The outer side of the fixing groove is provided with fixing holes for fixing terminals, and the terminals are electrically connected to the main transformer winding and the resonant winding.

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