A magnetic integrated transformer

Abstract

The present application discloses a magnetically integrated transformer, which relates to the technical field of transformers. It includes a housing, an insulating support is arranged inside the housing, a main magnetic core and an auxiliary magnetic core are arranged inside the insulating support. The main magnetic core and the auxiliary magnetic core are connected through an air gap, and a main winding is wound on the main magnetic core, an auxiliary winding is wound on the auxiliary magnetic core, and the main winding and the auxiliary winding are connected in parallel. By using a nanocrystalline alloy material for the main magnetic core, a ferrite material for the auxiliary magnetic core, connecting the main magnetic core and the auxiliary magnetic core through an air gap, and cooperating with the parallel connection mode of the main winding and the auxiliary winding, the present application can effectively balance the performance advantages of the two magnetic materials, improve the overall power density while ensuring high-frequency performance, reduce the risk of magnetic saturation and eddy current loss, thereby significantly improving the energy transmission efficiency.

Description

Technical Field

[0001] The present application relates to the technical field of transformers, and in particular to a magnetic integrated transformer. Background Art

[0002] As an important part of the power electronics field, transformer technology has achieved remarkable development in recent years. Traditional transformers are widely used in various power transmission and distribution scenarios due to their reliability and stability. However, as power electronic equipment develops towards high frequency and miniaturization, traditional transformers have gradually become inefficient, bulky, and overweight in high-frequency environments, which seriously restricts their application in high-performance scenarios. To meet this challenge, magnetic integration technology came into being. By optimizing the layout of magnetic components and material selection, it significantly improves the overall performance of the transformer and has become a hot spot in the development of current power electronics technology.

[0003] At present, in view of the limitations of traditional transformers, the industry generally adopts the method of optimizing winding structure or using new magnetic materials to improve them. The optimization of winding structure mainly introduces a multi-winding structure and increases the number of windings to achieve efficient energy transmission, thereby improving work efficiency and reducing volume and weight; the use of new magnetic materials usually selects ferrite cores or nanocrystalline alloy materials as cores, using their high-frequency characteristics to reduce core losses.

[0004] However, although the multi-winding structure can improve efficiency, it increases the complexity and manufacturing cost of the transformer, which is not conducive to large-scale application; the saturation magnetic induction intensity of the ferrite core is low, which limits the improvement of the power density of the transformer; and although the nanocrystalline alloy material has a high saturation magnetic induction intensity, it is difficult to give full play to its advantages in practical applications. Therefore, how to effectively balance the relationship between material performance and structural design has become a technical problem that needs to be solved urgently. Summary of the invention

[0005] In view of the problems existing in the prior art, the present application provides a magnetic integrated transformer.

[0006] The present application provides a magnetic integrated transformer, which adopts the following technical solution:

[0007] A magnetic integrated transformer comprises a shell, an insulating support is arranged in the shell, a main magnetic core and an auxiliary magnetic core are arranged in the insulating support, the main magnetic core is made of nanocrystalline alloy material, the auxiliary magnetic core is made of ferrite material, the central axes of the main magnetic core and the auxiliary magnetic core coincide, and the main magnetic core and the auxiliary magnetic core are connected by an air gap, a main winding is wound on the main magnetic core, an auxiliary winding is wound on the auxiliary magnetic core, and the main winding and the auxiliary winding are connected in parallel.

[0008] Optionally, the insulating support includes a first insulating sleeve, a second insulating sleeve and an insulating sleeve. The main magnetic core is installed in the first insulating sleeve, the auxiliary magnetic core is installed in the second insulating sleeve, the insulating sleeve is installed between the first insulating sleeve and the second insulating sleeve. The two ends of the insulating sleeve are respectively provided with a first crimping portion and a second crimping portion. The first insulating sleeve is provided with a first insertion slot for the first crimping portion to insert, and the first crimping portion is used to press the main magnetic core tightly. The second insulating sleeve is provided with a second insertion slot for the second crimping portion to insert, and the second crimping portion is used to press the auxiliary magnetic core tightly.

[0009] Optionally, the first crimping portion is fixedly arranged on the insulating sleeve. A sliding groove is arranged along the axial direction of the insulating sleeve at one end of the insulating sleeve away from the first crimping portion. The second crimping portion is slidably inserted into the sliding groove, and the insulating sleeve is provided with an elastic member for driving the second crimping portion to slide away from the insulating sleeve.

[0010] Optionally, a clamping block is arranged at the top end of the second insulating sleeve. A clamping groove for the clamping block to insert is arranged in the shell, and the clamping block is adapted to the clamping groove.

[0011] Optionally, both the first crimping portion and the second crimping portion are annular, and a plurality of notches are arranged on both the first crimping portion and the second crimping portion.

[0012] Optionally, a plurality of connection ports are arranged on the side walls of the first insulating sleeve and the second insulating sleeve. A heat conducting sheet is fixedly arranged in each connection port. An installation port is arranged on the side wall of the shell, and a heat sink is fixedly arranged in the installation port. Heat conducting silica gel is filled between the heat conducting sheet and the heat sink in the shell.

[0013] Optionally, an insulating film is arranged at one end of each heat conducting sheet close to the inside of the first insulating sleeve or the second insulating sleeve.

[0014] Optionally, a plurality of heat conducting blocks are arranged on one side of the heat conducting sheet away from the inside of the first insulating sleeve or the second insulating sleeve. The heat conducting blocks are integrally formed with the heat conducting sheet.

[0015] Optionally, a heat exchange cavity is arranged in the shell. The installation port is communicated with the heat exchange cavity, and one end of the heat sink is located in the heat exchange cavity. The heat exchange cavity is provided with a through hole communicated with the inside of the shell. The bottom end of the first insulating sleeve covers the position of the through hole, and the first insulating sleeve is provided with a heat exchange hole communicated with the through hole.

[0016] Optionally, a cold source inlet and a cold source outlet are arranged on the heat sink. A heat exchange copper tube is arranged in the heat exchange cavity, and the two ends of the heat exchange copper tube are respectively communicated with the cold source inlet and the cold source outlet.

[0017] In summary, the present application includes at least one of the following beneficial technical effects:

[0018] 1. In the present application, the main magnetic core is made of nanocrystalline alloy material, the auxiliary magnetic core is made of ferrite material, the main magnetic core and the auxiliary magnetic core are connected through an air gap, and in combination with the parallel connection mode of the main winding and the auxiliary winding, the performance advantages of the two magnetic materials can be effectively balanced, the overall power density can be improved while ensuring high-frequency performance, the risk of magnetic saturation can be effectively reduced, and at the same time, a significant improvement in energy transmission efficiency is achieved. In addition, this structural design not only optimizes the magnetic flux distribution, but also can reduce the eddy current loss to a certain extent, thereby prolonging the service life of the transformer and reducing the operating cost, thus improving the overall performance.

[0019] 2. In the present application, the main magnetic core and the auxiliary magnetic core are respectively installed in the first insulating sleeve and the second insulating sleeve. When the insulating support is installed on the housing, under the elastic force of the elastic member, the second crimping portion presses the auxiliary magnetic core. At the same time, the insulating sleeve can automatically adjust its position under the reaction force of the elastic member, so that the first crimping portion presses the main magnetic core, thereby effectively improving the installation stability of the main magnetic core and the auxiliary magnetic core, preventing the main magnetic core or the auxiliary magnetic core from shaking due to installation errors or external impacts, and thus prolonging the service life of the transformer.

[0020] 3. In the present application, a plurality of heat conducting fins are provided on the side walls of the first insulating sleeve and the second insulating sleeve, an installation opening is provided on the side wall of the housing and a heat sink is fixedly arranged, and heat conducting silicone is filled between the heat conducting fins and the heat sink, thereby forming an efficient heat conduction path. In combination with an air cooling system or a liquid cooling system to quickly cool the heat sink, the heat dissipation performance of the transformer can be significantly improved, ensuring the temperature stability of the transformer during high-power operation, and improving the operation stability and reliability of the transformer.

[0021] 4. In the present application, a heat exchange cavity is provided in the housing, the installation opening is communicated with the heat exchange cavity, one end of the heat sink is located in the heat exchange cavity. At the same time, the hot air in the first insulating cover and the second insulating cover can sequentially enter the heat exchange cavity through the heat exchange holes and the through holes and exchange heat with the heat sink, thereby reducing the problems of performance degradation and shortened service life caused by heat accumulation inside the transformer, and further improving the operation stability and reliability of the transformer. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 is the overall structural schematic diagram of an embodiment of the present application;

[0023] Figure 2 is the structural sectional view of an embodiment of the present application.

[0024] Description of reference numerals: 1. Housing; 11. Card slot; 12. Heat sink; 121. Cold source inlet; 122. Cold source outlet; 13. Thermal conductive silicone; 14. Heat exchange cavity; 15. Through hole; 16. Heat exchange copper tube; 2. Insulating support; 21. First insulating sleeve; 211. Heat exchange hole; 22. Second insulating sleeve; 221. Clamping block; 23. Insulating sleeve; 231. First crimping portion; 232. Second crimping portion; 233. Elastic member; 234. Notch; 24. Heat conductive sheet; 241. Insulating film; 242. Heat conduction block; 3. Main magnetic core; 31. Main winding; 4. Auxiliary magnetic core; 41. Auxiliary winding. Detailed implementation manners

[0025] The following will combine the attached Figure 1 - attached Figure 2 to clearly and completely describe the technical solutions in the embodiments of the present invention. The described embodiments are only possible technical implementations of the present invention, not all possible implementations. Those skilled in the art can fully combine the embodiments of the present invention and obtain other embodiments without creative work, and these embodiments are also within the protection scope of the present invention.

[0026] The inventors of the present application found that existing magnetically integrated transformers generally adopt a multi-winding structure or use new magnetic materials such as ferrite cores and nanocrystalline alloys as cores to optimize the overall performance of magnetically integrated transformers. However, although the multi-winding structure can improve efficiency, it increases the complexity and manufacturing cost of the transformer and is not conducive to large-scale applications; the saturation magnetic induction intensity of ferrite cores is relatively low, which limits the improvement of the power density of the transformer; although nanocrystalline alloy materials have a relatively high saturation magnetic induction intensity, it is difficult to fully utilize their advantages in actual applications. For this reason, the present application discloses a magnetically integrated transformer, mainly adopting the following solutions:

[0027] An embodiment of the present application discloses a magnetically integrated transformer. Refer to Figure 1 、 2 , including a housing 1, an insulating support 2 is arranged inside the housing 1, a main magnetic core 3 and an auxiliary magnetic core 4 are arranged inside the insulating support 2. Among them, the central axes of the main magnetic core 3 and the auxiliary magnetic core 4 coincide, and the main magnetic core 3 and the auxiliary magnetic core 4 are connected by an air gap. A main winding 31 is wound around the main magnetic core 3, an auxiliary winding 41 is wound around the auxiliary magnetic core 4, and the main winding 31 and the auxiliary winding 41 are connected in parallel.

[0028] Refer to Figure 1, Specifically, the main magnetic core 3 is made of nanocrystalline alloy material, and the auxiliary magnetic core 4 is made of ferrite material. The nanocrystalline alloy material has a high saturation magnetic induction intensity and low core loss, while the ferrite material has good high-frequency characteristics and low cost. By selecting different materials for the main magnetic core 3 and the auxiliary magnetic core 4 respectively and connecting them through an air gap, the advantages of the two materials can be fully utilized, improving the overall power density while ensuring high-frequency performance, reducing the risk of magnetic saturation, and significantly enhancing the energy transmission efficiency.

[0029] Refer to Figure 2 , Specifically, the main winding 31 adopts a multi-layer winding structure. Each layer of winding is wound by a copper wire, and the diameter of the copper wire can be adjusted according to the magnitude of the current. For example, a copper wire with a diameter of 0.5 mm to 1.2 mm can be selected. The windings of each layer are connected in parallel, and a polyimide film or high-temperature tape is provided between the copper wires of adjacent layers, which has good high-temperature resistance and insulation performance and can prevent the occurrence of short circuits. The auxiliary winding 41 also adopts a multi-layer winding structure, and the windings of each layer are connected in series, and a polyimide film or high-temperature tape is also provided between the copper wires of adjacent layers.

[0030] Refer to Figure 2 , Specifically, the insulating support 2 includes a first insulating sleeve 21, a second insulating sleeve 22, and an insulating sleeve 23. The internal structure of the first insulating sleeve 21 is adapted to the main magnetic core 3, and the main magnetic core 3 is installed in the first insulating sleeve 21. The internal structure of the second insulating sleeve 22 is adapted to the auxiliary magnetic core 4, and the auxiliary magnetic core 4 is installed in the second insulating sleeve 22. The first insulating sleeve 21 and the second insulating sleeve 22 can be made of materials with high temperature resistance and corrosion resistance, such as polytetrafluoroethylene.

[0031] Refer to Figure 2 , The insulating sleeve 23 is installed between the first insulating sleeve 21 and the second insulating sleeve 22. The two ends of the insulating sleeve 23 are respectively provided with a first crimping portion 231 and a second crimping portion 232. The first crimping portion 231 is integrally formed with the insulating sleeve 23. A chute is slidably provided along the axial direction of the insulating sleeve 23 at one end of the insulating sleeve 23 away from the first crimping portion 231. The second crimping portion 232 is slidably inserted into the chute. The insulating sleeve 23 is provided with an elastic member 233 for driving the second crimping portion 232 to slide away from the insulating sleeve 23. The elastic member 233 can adopt a compression spring or an elastic retaining ring. The first insulating sleeve 21 is provided with a first insertion slot, which is adapted to the first crimping portion 231 and is used for inserting the first crimping portion 231. The second insulating sleeve 22 is provided with a second insertion slot, which is adapted to the second crimping portion 232 and is used for inserting the second crimping portion 232.

[0032] When the insulating support 2 is installed on the housing 1, under the elastic force of the elastic member 233, the second crimping portion 232 presses the auxiliary magnetic core 4 tightly. At the same time, the insulating sleeve 23 can automatically adjust its position under the reaction force of the elastic member 233, so that the first crimping portion 231 presses the main magnetic core 3 tightly, thereby effectively improving the installation stability of the main magnetic core 3 and the auxiliary magnetic core 4, preventing the main magnetic core 3 or the auxiliary magnetic core 4 from shaking due to installation errors or external impacts, and thus extending the service life of the transformer.

[0033] Refer to Figure 2 , Further, both the first crimping portion 231 and the second crimping portion 232 are annular, and a plurality of notches 234 are provided on both the first crimping portion 231 and the second crimping portion 232. Through this structural design, not only can the main magnetic core 3 and the auxiliary magnetic core 4 be effectively pressed, but also the local interruption of the magnetic circuit is realized by using the notches 234, thereby reducing the eddy current effect, reducing energy loss, and improving the overall efficiency and performance of the transformer.

[0034] Refer to Figure 2 , Still further, a clamping block 221 is provided at the top of the second insulating sleeve 22, and a clamping groove 11 for inserting the clamping block 221 is provided in the housing 1, and the clamping block 221 is adapted to the clamping groove 11; by providing the clamping block 221 at the top of the second insulating sleeve 22 and providing the clamping groove 11 adapted to the clamping block 221 in the housing 1, when the insulating support 2 is installed on the housing 1, the clamping block 221 on the second insulating sleeve 22 is inserted into the clamping groove 11 in the housing 1, and through the arrangement of the elastic member 233, by squeezing the first insulating sleeve 21 and the second insulating sleeve 22, the first insulating sleeve 21 and the second insulating sleeve 22 are close to each other, facilitating the installation of the insulating support 2. After the insulating support 2 is installed on the housing 1, the first insulating sleeve 21 and the second insulating sleeve 22 can respectively abut against the upper and lower side walls in the housing 1 under the elastic force of the elastic member 233, thereby ensuring the installation stability of the insulating support 2.

[0035] Refer to Figure 2, To improve the heat dissipation performance of the transformer and ensure its working stability and reliability, a plurality of connection ports are provided on the side walls of the first insulating sleeve 21 and the second insulating sleeve 22. A heat conducting sheet 24 is fixedly arranged in each connection port. An installation port is provided on the side wall of the housing 1, and a heat sink 12 is fixedly arranged in the installation port. A heat conducting silicone 13 is filled between the heat conducting sheet 24 and the heat sink 12 inside the housing 1. Both the heat conducting sheet 24 and the heat sink 12 are made of materials with good heat conduction performance such as copper or aluminum. Through this structural design, an efficient heat conduction path can be formed to quickly conduct the high temperature inside the transformer to the outside of the transformer, significantly improving the heat dissipation performance of the transformer. Further, when the transformer is in use, it can be combined with an air cooling system or a liquid cooling system to quickly cool the heat sink 12, further improving the heat dissipation performance of the transformer and ensuring the temperature stability of the transformer during high-power operation.

[0036] Refer to Figure 2 , An insulating film 241 is provided at one end of each heat conducting sheet 24 close to the inside of the first insulating sleeve 21 or the second insulating sleeve 22. Through this structural design, it can effectively prevent a short circuit between the heat conducting sheet 24 and the main magnetic core 3 or the auxiliary magnetic core 4, improving safety. For example, the insulating film 241 can be made of polyimide film or high-temperature tape, which has good high-temperature resistance and insulation performance.

[0037] Refer to Figure 1 , 2 , A number of heat conducting blocks 242 are provided on the side of the heat conducting sheet 24 away from the inside of the first insulating sleeve 21 or the second insulating sleeve 22. The heat conducting blocks 242 are integrally formed with the heat conducting sheet 24. The setting of the heat conducting blocks 242 increases the contact area between the heat conducting sheet 24 and the heat sink 12, effectively improving the heat transfer efficiency and further enhancing the heat dissipation performance of the transformer. In addition, the design of integrally forming the heat conducting blocks 242 with the heat conducting sheet 24 ensures the structural stability and reliability, reduces the thermal resistance problem caused by poor connection, thus ensuring the temperature stability of the transformer during high-power operation and extending the service life of the equipment.

[0038] Refer to Figure 2 , A heat exchange cavity 14 is provided inside the housing 1. The installation port is communicated with the heat exchange cavity 14, and one end of the heat sink 12 is located inside the heat exchange cavity 14. The heat exchange cavity 14 is provided with a through hole 15 communicated with the inside of the housing 1. The bottom end of the first insulating sleeve 21 covers the position of the through hole 15, and the first insulating sleeve 21 is provided with a heat exchange hole 211 communicated with the through hole 15. Through this structural design, the hot air inside the first insulating sleeve 21 and the second insulating sleeve 22 can sequentially enter the heat exchange cavity 14 through the heat exchange hole 211 and the through hole 15 and perform heat exchange with the heat sink 12, thereby reducing the problems of performance degradation and shortened service life caused by heat accumulation inside the transformer and further improving the operation stability and reliability of the transformer.

[0039] Refer toFigure 1 , 2 , a cold source inlet 121 and a cold source outlet 122 are provided on the heat sink 12, a heat exchange copper tube 16 is provided in the heat exchange cavity 14, and both ends of the heat exchange copper tube 16 are respectively communicated with the cold source inlet 121 and the cold source outlet 122. Through this structural design, during use, the cold source inlet 121 and the cold source outlet 122 can be connected to an air cooling system or a liquid cooling system, further improving the heat exchange efficiency and heat dissipation effect inside the transformer.

[0040] The implementation principle of a magnetic integrated transformer in an embodiment of the present application is as follows: By using a nanocrystalline alloy material for the main magnetic core 3, a ferrite material for the auxiliary magnetic core 4, connecting the main magnetic core 3 and the auxiliary magnetic core 4 through an air gap, and cooperating with the parallel connection mode of the main winding 31 and the auxiliary winding 41, the performance advantages of the two magnetic materials can be effectively balanced, while ensuring high-frequency performance, the overall power density is improved, the risk of magnetic saturation is effectively reduced, and at the same time, a significant improvement in energy transmission efficiency is achieved. In addition, this structural design not only optimizes the magnetic flux distribution but also can reduce eddy current losses to a certain extent, thereby extending the service life of the transformer and reducing the operating cost, thus improving the overall performance.

[0041] The above are all preferred embodiments of the present application, and the protection scope of the present application is not limited thereby. Therefore, all equivalent changes made according to the structure, shape, and principle of the present application should be covered within the protection scope of the present application.

Claims

1. A magnetic integrated transformer, characterized in that: It includes a housing (1), an insulating support (2) is arranged inside the housing (1), a main magnetic core (3) and an auxiliary magnetic core (4) are arranged inside the insulating support (2), the main magnetic core (3) is made of nanocrystalline alloy material, the auxiliary magnetic core (4) is made of ferrite material, the central axes of the main magnetic core (3) and the auxiliary magnetic core (4) coincide, and the main magnetic core (3) and the auxiliary magnetic core (4) are connected through an air gap, and a main winding (31) is wound around the main magnetic core (3), an auxiliary winding (41) is wound around the auxiliary magnetic core (4), and the main winding (31) and the auxiliary winding (41) are connected in parallel; The insulating support (2) includes a first insulating sleeve (21), a second insulating sleeve (22) and an insulating sleeve (23). The main magnetic core (3) is installed inside the first insulating sleeve (21), the auxiliary magnetic core (4) is installed inside the second insulating sleeve (22), the insulating sleeve (23) is installed between the first insulating sleeve (21) and the second insulating sleeve (22). The two ends of the insulating sleeve (23) are respectively provided with a first crimping part (231) and a second crimping part (232). The first insulating sleeve (21) is provided with a first insertion slot for the first crimping part (231) to insert, and the first crimping part (231) is used to compress the main magnetic core (3). The second insulating sleeve (22) is provided with a second insertion slot for the second crimping part (232) to insert, and the second crimping part (232) is used to compress the auxiliary magnetic core (4); The first crimping part (231) is fixedly arranged on the insulating sleeve (23). A sliding groove is arranged axially along the insulating sleeve (23) at one end of the insulating sleeve (23) far from the first crimping part (231). The second crimping part (232) slidably penetrates through the sliding groove, and the insulating sleeve (23) is provided with an elastic member (233) for driving the second crimping part (232) to slide away from the insulating sleeve (23).

2. The magnetic integrated transformer according to claim 1, characterized in that: A clamping block (221) is arranged at the top end of the second insulating sleeve (22). A clamping groove (11) for the clamping block (221) to insert is arranged inside the housing (1), and the clamping block (221) is adapted to the clamping groove (11).

3. The magnetic integrated transformer according to claim 1, wherein: Both the first crimping part (231) and the second crimping part (232) are annular, and a plurality of notches (234) are arranged on both the first crimping part (231) and the second crimping part (232).

4. A magnetic integrated transformer according to claim 1, wherein: A plurality of connection ports are opened on the side walls of the first insulating sleeve (21) and the second insulating sleeve (22). A heat conduction sheet (24) is fixedly arranged in each connection port. An installation port is opened on the side wall of the housing (1), and a heat sink (12) is fixedly arranged in the installation port. Heat conduction silicone (13) is filled inside the housing (1) between the heat conduction sheet (24) and the heat sink (12).

5. A magnetic integrated transformer according to claim 4, characterized in that: An insulating film (241) is arranged at one end of each heat conduction sheet (24) close to the inside of the first insulating sleeve (21) or the second insulating sleeve (22).

6. A magnetic integrated transformer according to claim 4, characterized in that: On one side of the heat conducting sheet (24) away from the inside of the first insulating sleeve (21) or the second insulating sleeve (22), a plurality of heat conducting blocks (242) are provided, and the heat conducting blocks (242) are integrally formed with the heat conducting sheet (24).

7. A magnetic integrated transformer according to claim 4, characterized in that: An exchange cavity (14) is arranged in the housing (1), the installation opening is communicated with the exchange cavity (14), one end of the heat dissipation fin (12) is located in the exchange cavity (14), a through hole (15) communicated with the inside of the housing (1) is arranged in the exchange cavity (14), the bottom end of the first insulating sleeve (21) covers the position of the through hole (15), and an exchange hole (211) communicated with the through hole (15) is arranged in the first insulating sleeve (21).

8. A magnetic integrated transformer according to claim 7, wherein: A cold source inlet (121) and a cold source outlet (122) are arranged on the heat dissipation fin (12), an exchange copper tube (16) is arranged in the exchange cavity (14), and two ends of the exchange copper tube (16) are respectively communicated with the cold source inlet (121) and the cold source outlet (122).

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