High-power magnetic combination DC transformer assembly
By "borrowing" the core of the output inductor and the core of the external magnetic components in the DC transformer assembly, the problems of large space and high cost in the prior art are solved, and the effect of shortening product length and reducing cost is achieved.
Patent Information
- Application Number
- CN202510281070.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-03-11
- Publication Date
- 2025-06-10
AI Technical Summary
In the design of existing DC transformer components, the space occupies a large amount of space and is costly, mainly because the independent DC transformer and the output inductor use two pairs of magnetic cores.
By "borrowing" the magnetic core of the output inductor and the DC transformer core form a DC transformer, and the core of the external magnetic element and the output inductor core form an output inductor, thereby reducing the use of the magnetic core.
It achieves shortening of product length, space and cost reduction, and is also suitable for use in DC components of different powers.
Smart Images
Figure CN120126901A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a DC transformer, and more particularly to a high-power magnetic combination DC transformer assembly. Background Art
[0002] Most of the existing DC (direct current) transformer assemblies are designed conventionally as Figure 1 shown. The DC transformer and the output inductor are independent, each using a pair of magnetic cores (formed by buckling two on the left and right). For example, the DC transformer uses two magnetic cores ① and ② buckled on the left and right, and the output inductor uses two magnetic cores ③ and ④ buckled on the left and right. The main defect of this design is that it occupies a large space and has a relatively high cost. Summary of the Invention
[0003] In view of this, the present invention proposes an improved high-power magnetic combination DC transformer assembly to solve the problems existing in the above-mentioned prior art.
[0004] A high-power magnetic combination DC transformer assembly includes: a DC transformer magnetic core, a primary winding, a secondary winding, an output inductor magnetic core, an output inductor winding, and a base; the primary winding and the secondary winding are assembled with the DC transformer magnetic core, one side of the DC transformer magnetic core abuts against the output inductor magnetic core, so that the primary winding and the secondary winding are located between the DC transformer magnetic core and the output inductor magnetic core, and together with the DC transformer magnetic core and the output inductor magnetic core form a DC transformer; the output inductor winding is assembled on the other side of the output inductor magnetic core, and the other side of the output inductor magnetic core is arranged to be docked with the magnetic core of an external magnetic component, so that the output inductor winding, the output inductor magnetic core and the magnetic core of the external magnetic component together form an output inductor; the DC transformer and the output inductor are both fixed on the base, and the primary winding, the secondary winding and the output inductor winding all lead out from the base.
[0005] Further, the primary winding includes a plurality of coils, the secondary winding includes a plurality of copper sheets, and the copper sheets are arranged to conduct large currents.
[0006] Further, the plurality of coils and the plurality of copper sheets are interpenetrated and assembled on the DC transformer magnetic core.
[0007] Further, the top of the copper sheet is bent.
[0008] Further, it further includes: a metal heat sink, which is arranged on the DC transformer magnetic core and is used to conduct away the heat generated by the DC transformer magnetic core.
[0009] Further, the metal heat sink is adhered to the DC transformer magnetic core by thermal conductive glue.
[0010] Furthermore, the output inductor winding is a flat coil and is configured to carry a large current.
[0011] Furthermore, a heat conduction block is filled between the flat coil and the output inductor core.
[0012] Furthermore, the heat conduction block includes a pair of ceramic heat conduction blocks, which are symmetrically arranged in the gap formed between the flat coil and the output inductor core.
[0013] Furthermore, the base is a plastic-coated copper bar base.
[0014] The beneficial effects of the technical solution of the present invention are reflected in: on the one hand, by "borrowing" the core of the output inductor, the present invention constitutes the DC transformer in the DC transformer assembly of the present invention together with the DC transformer core, the primary winding, and the secondary winding; on the other hand, by "borrowing" the core of an external magnetic component (such as the core of an on-board charger OBC transformer), the present invention constitutes the output inductor in the DC transformer assembly of the present invention together with the output inductor core and the output inductor winding. In this way, compared with the existing DC transformer assembly, the present invention can save the use of two cores, greatly shortening the length of the product and significantly reducing the occupied space and cost. BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Figure 1 is a conventional design of an existing DC transformer assembly.
[0016] Figure 2 is a schematic structural diagram of a high-power magnetic combination DC transformer assembly provided by an embodiment of the present invention.
[0017] Figure 3 is an exploded view of the structure of a high-power magnetic combination DC transformer assembly provided by an embodiment of the present invention.
[0018] Figure 4 is a schematic diagram of the assembly of a high-power magnetic combination DC transformer assembly and an OBC transformer provided by an embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS
[0019] The present invention will be further described below with reference to the drawings and specific embodiments and examples. At the same time, it should be understood that the purpose of providing the embodiments is only for illustration and not for any limitation.
[0020] In addition, the spatial orientation terms such as "upper", "lower", "left", "right", "top", and "bottom" used in the description of the technical solution of the present invention are for facilitating the description of the relative positional relationship between the components of the product, and do not mean that the product has only the orientation shown in the figure. During actual use, with the different orientations of the product (such as rotating 90 degrees or other orientations), the spatial-related descriptions for describing its orientation should also be explained in a similar manner.
[0021] Please refer to Figure 2 and Figure 3 , an embodiment of the present invention provides a high-power magnetic combination DC transformer assembly, including: a DC transformer core 1, a self-adhesive insulated wire coil 2, a formed copper sheet 3, an output inductor core 4, a flat coil 5, and a plastic-coated copper bar base 6. Among them, the coil 2 is used as the primary winding, the copper sheet 3 is used as the secondary winding and is assembled with the DC transformer core 1. At the same time, one side of the DC transformer core 1 abuts against the output inductor core 4, so that the coil 2 and the copper sheet 3 are located between the DC transformer core 1 and the output inductor core 4, and together with the DC transformer core 1 and the output inductor core 4, they form a DC transformer; the flat coil 5 is used as the output inductor winding and is assembled on the other side of the output inductor core 4, and the other side of the output inductor core 4 is set to be able to dock with the core of an external magnetic component, so that the flat coil 5, the output inductor core 4, and the core of the external magnetic component together form an output inductor; the DC transformer and the output inductor are both fixed on the base 6, and the coil 2 (primary winding), the copper sheet 3 (secondary winding), and the flat coil 5 (output inductor winding) all lead out from the corresponding through holes opened on the base 6, thus forming the DC transformer assembly of the embodiment of the present invention.
[0022] It should be understood that the primary winding is not limited to the form of a self-adhesive insulated wire coil, and other forms of coils can also be used; the secondary winding is not limited to the form of a formed copper sheet, and other large-current-carrying winding forms can also be used. Similarly, the winding of the output inductor is not limited to the form of a flat coil. Those skilled in the art can make corresponding deformations and adjustments according to actual design requirements, and the present invention does not limit the primary winding, the secondary winding, and the output inductor winding.
[0023] The primary winding of the DC transformer may include several coils 2, and the secondary winding may include several copper sheets 3. The copper sheet 3, as the secondary winding, can carry a large current. For example, Figure 2 in the shown embodiment, the primary winding of the DC transformer includes 3 coils 2, and the secondary winding includes two groups of copper sheets 3. The coils 2 and the copper sheets 3 are interspersed and stacked and assembled on the core 1, and a group of copper sheets 3 is interspersed between every two adjacent coils 2. It should be understood that, Figure 2Merely for the sake of exemplification, the number of coils of the primary winding can be other numbers, and the number of copper sheets of the secondary winding can also be other numbers. The present invention does not impose any limitations in this regard.
[0024] For example Figure 3 , in a preferred embodiment, as the secondary winding for passing a large current, the top of the copper sheet 3 is bent to increase the heat dissipation effect.
[0025] In addition, on the opposite two side surfaces of the outside of the DC transformer core 1, metal heat sinks 7 are respectively pasted with thermal conductive glue to more quickly conduct the heat on the core 1 to the heat dissipation cavity on the client side.
[0026] In some embodiments, since the output inductance winding also passes a large current, in order to increase the heat dissipation effect, as Figure 3 shown, a heat conductive block 8 is filled between the flat coil 5 and the output inductance core 4. Specifically, the heat conductive block 8 includes a pair of profiled ceramic heat conductive blocks, which are symmetrically arranged in the top gap formed between the flat coil 5 and the output inductance core 4. By "profiled" it means that the shape of the ceramic block (especially the inner arc, etc.) is made according to the flat coil 5. In order to further increase the heat dissipation effect, thermal conductive glue can be applied at this gap and then the ceramic block can be glued in.
[0027] The assembled DC transformer and the output inductance are fixed to the base 6 together to form a high-power magnetic combination DC transformer assembly, which can be used in combination with an OBC (on-board charger) transformer. As Figure 4 shown, the part framed in blue represents the OBC transformer, and the part framed in red represents the DC transformer assembly of the present invention. The core principle is that the DC transformer "borrows" the core of the output inductance, and the output inductance "borrows" the core of the OBC transformer to form a closed magnetic circuit in this way. In this way, compared with the design of the prior art, the DC transformer assembly of the present invention reduces the use of two cores, the length of the product is shortened, the occupied space is greatly reduced, and the cost is also reduced, bringing many technical advantages at one stroke. And it is suitable for DC components with different powers, such as 1-9KW, etc.
[0028] It should be understood that the combination with the OBC transformer is only an example. The DC transformer assembly of the present invention can also be used in combination with other magnetic components, as long as the output inductance core is docked with the core of other magnetic components to form a pair of cores.
[0029] In the present invention, the form of the cores of the DC transformer and the output inductance is not limited, and can be an EQ core, an ER core, an EE core, a UF core, a UU core, an EFD core, etc.
[0030] The above content is a further detailed description of the present invention in combination with specific preferred embodiments. It cannot be determined that the specific implementation of the present invention is only limited to these descriptions. For those skilled in the art of the present invention, without departing from the concept of the present invention, several equivalent substitutions or obvious modifications can be made, and if the performance or use is the same, they should all be regarded as falling within the protection scope of the present invention.
Claims
1. A high-power magnetic combination DC transformer assembly, characterized in that: include: DC transformer core, primary winding, secondary winding, output inductor core, output inductor winding and base; The primary winding and the secondary winding are assembled with the DC transformer core, and the DC transformer core is in contact with one side of the output inductor core, so that the primary winding and the secondary winding are located between the DC transformer core and the output inductor core, and together with the DC transformer core and the output inductor core, form a DC transformer; The output inductor winding is assembled on the other side of the output inductor magnetic core, and the other side of the output inductor magnetic core is configured to be connected to a magnetic core of an external magnetic element, so that the output inductor winding, the output inductor magnetic core and the magnetic core of the external magnetic element together constitute an output inductor; The DC transformer and the output inductor are both fixed on the base, and the primary winding, the secondary winding and the output inductor winding are all connected from the base.
2. The high-power magnetic combination DC transformer assembly according to claim 1, characterized in that: The primary winding includes a plurality of coils, and the secondary winding includes a plurality of copper sheets, and the copper sheets are configured to be able to pass a large current.
3. The high-power magnetic combination DC transformer assembly according to claim 2, characterized in that: The plurality of coils and the plurality of copper sheets are interlaced and assembled on the magnetic core of the DC transformer.
4. The high-power magnetic combination DC transformer assembly according to claim 2, characterized in that: The top of the copper sheet is bent.
5. The high-power magnetic combination DC transformer assembly according to any one of claims 1 to 4, characterized in that: Also includes: The metal heat sink is arranged on the DC transformer core and is used for conducting away the heat generated by the DC transformer core.
6. The high-power magnetic combination DC transformer assembly according to claim 5, characterized in that: The metal heat sink is bonded to the DC transformer core by heat-conducting adhesive.
7. The high-power magnetic combination DC transformer assembly according to claim 1, characterized in that: The output inductor winding is a flat coil and is configured to be able to pass a large current.
8. The high-power magnetic combination DC transformer assembly according to claim 7, characterized in that: A heat conductive block is filled between the flat coil and the output inductor magnetic core.
9. The high-power magnetic combination DC transformer assembly according to claim 7, characterized in that: The heat conductive block comprises a pair of ceramic heat conductive blocks, which are symmetrically arranged in a gap formed between the flat coil and the output inductor magnetic core.
10. The high-power magnetic combination DC transformer assembly according to claim 1, characterized in that: The base is a plastic-coated copper busbar base.