Integrated transformer and power module

Abstract

The invention provides an integrated transformer and a power module, and relates to the technical field of transformers. The integrated transformer comprises two magnetic cores, each magnetic core comprises two magnetic yokes and two magnetic columns, and the two magnetic yokes are oppositely arranged in the first direction; the two magnetic columns are located between the two magnetic yokes and are oppositely arranged in the second direction, and an included angle larger than 0 degree is formed between the second direction and the first direction; one magnetic yoke in one magnetic core is connected with one magnetic yoke in the other magnetic core through one short-circuit magnetic block, so that the two magnetic cores are connected in series to form a ring; the four first windings are respectively wound on the four magnetic columns of the two magnetic cores; the at least one second winding is wound on the magnetic core or the short-circuit magnetic block; the directions of magnetic fluxes generated by the second winding in the two magnetic columns of any magnetic core are the same. The main transformer and the auxiliary transformer can be integrated, and the efficiency and the power density of the auxiliary transformer are improved; the main transformer and the auxiliary transformer do not interfere with each other.

Description

Background Art

[0002] In a power module, there is a need for a main transformer that undertakes the main power conversion and an auxiliary transformer that can undertake the auxiliary power conversion. In the related art, one way is to set up a separate auxiliary isolation transformer to cooperate with the auxiliary power supply. However, in this way, the auxiliary transformer set up is not integrated with the main transformer, there are many magnetic components and a large volume difference, and the overall structure is relatively messy, resulting in a very low power density of the power module; due to volume limitations, the efficiency of a separate auxiliary power supply is often low. Another way is to add an additional output to the main transformer as the auxiliary transformer. However, this integration method requires that the two outputs must have the same frequency and the same input source, otherwise interference between them cannot be avoided. Therefore, such an integration scheme has quite limited flexibility in control and system architecture.

[0003] It should be noted that the information disclosed in the above Background Art section is only used to enhance the understanding of the background of the present disclosure, and thus may include information that does not constitute the prior art known to those of ordinary skill in the art. Summary of the Invention

[0004] The present disclosure provides an integrated transformer and a power module, which at least overcome to a certain extent the problems of low efficiency, low power density, and high coupling and mutual interference between inputs in the related art.

[0005] Other features and advantages of the present disclosure will become apparent through the following detailed description, or will be learned in part through the practice of the present disclosure.

[0006] According to a first aspect of the present disclosure, there is provided an integrated transformer, comprising:

[0007] Two magnetic cores, each magnetic core comprising two magnetic yokes and two magnetic columns, the two magnetic yokes being disposed opposite to each other in a first direction; the two magnetic columns being located between the two magnetic yokes, and the two magnetic columns being disposed opposite to each other in a second direction, the second direction having an included angle with the first direction, the included angle being greater than 0 degrees;

[0008] Two short-circuit magnetic blocks, one magnetic yoke in one magnetic core being connected to one magnetic yoke in the other magnetic core through one short-circuit magnetic block to connect the two magnetic cores in series to form a loop;

[0009] Four first windings, respectively wound around the four magnetic columns of the two magnetic cores;

[0010] At least one second winding, the second winding being wound around the magnetic core or the short-circuit magnetic block; wherein, the magnetic flux directions generated by the second winding in the two magnetic columns of any one magnetic core are the same.

[0011] In some embodiments of the present disclosure, each of the first windings includes a first primary winding and a first secondary winding;

[0012] The first primary windings wound around two magnetic posts of the same magnetic core are connected in series;

[0013] The first secondary windings wound around two magnetic posts of the same magnetic core are connected in series.

[0014] In some embodiments of the present disclosure, the number of turns of the first primary windings on two magnetic posts of the same magnetic core is the same, and the number of turns of the first secondary windings on two magnetic posts of the same magnetic core is the same.

[0015] In some embodiments of the present disclosure, the ratio of the exciting magnetic fluxes generated by the second winding in two magnetic posts of the same magnetic core is a first ratio;

[0016] The ratio of the number of turns of the first primary winding wound around the two magnetic posts of the same magnetic core is a second ratio;

[0017] The product of the first ratio and the second ratio is one;

[0018] The ratio of the number of turns of the first secondary winding wound around the two magnetic posts of the same magnetic core is the same as the second ratio.

[0019] In some embodiments of the present disclosure, each magnetic post is a cuboid, and the magnetic post includes two surfaces connected to the magnetic yoke and four sequentially connected side surfaces;

[0020] The four side surfaces include two relatively arranged first side surfaces and two relatively arranged second side surfaces. The first side surfaces and the second side surfaces are connected, and the area of the first side surfaces is larger than that of the second side surfaces;

[0021] The first side surfaces are parallel to the first direction and parallel to the second direction;

[0022] The second side surfaces are parallel to the first direction and perpendicular to the second direction.

[0023] In some embodiments of the present disclosure, the two magnetic cores are arranged along the second direction;

[0024] Wherein, along the first direction, two magnetic yokes on the same side of the two magnetic cores are connected by the short-circuit magnetic block.

[0025] In some embodiments of the present disclosure, the two magnetic cores are arranged along the third direction;

[0026] The third direction is perpendicular to the first direction and the second direction;

[0027] Among them, along the first direction, two yokes on the same side of the two magnetic cores are connected by the short-circuit magnetic block.

[0028] In some embodiments of the present disclosure, the second winding includes a second primary winding and a second secondary winding.

[0029] In some embodiments of the present disclosure, the second primary winding and the second secondary winding are concentrically wound around two magnetic posts of any one of the magnetic cores.

[0030] In some embodiments of the present disclosure, the number of the second windings is two;

[0031] Each of the second windings is wound around two magnetic posts of the same magnetic core.

[0032] In some embodiments of the present disclosure, the second primary winding and the second secondary winding are concentrically wound around any one of the yokes of any one of the magnetic cores.

[0033] In some embodiments of the present disclosure, the number of the second windings is four;

[0034] One of the second windings is wound around each of the four yokes of the two magnetic cores.

[0035] In some embodiments of the present disclosure, the second primary winding and the second secondary winding are concentrically wound around any one of the short-circuit magnetic blocks.

[0036] In some embodiments of the present disclosure, the number of the second windings is two;

[0037] The two second windings are respectively wound around the two short-circuit magnetic blocks.

[0038] In some embodiments of the present disclosure, the provided integrated transformer further includes: an insulating structure;

[0039] Each of the first windings includes a first primary winding and a first secondary winding;

[0040] Among them, the insulating structure is used to isolate the first primary winding and the first secondary winding, and to isolate the second primary winding and the second secondary winding.

[0041] In some embodiments of the present disclosure, two short-circuit magnetic blocks are arranged between the two yokes of the two magnetic cores, and an air gap is arranged between the two short-circuit magnetic blocks.

[0042] In some embodiments of the present disclosure, each of the short-circuit magnetic blocks is integrally formed with the adjacent yoke.

[0043] In some embodiments of the present disclosure, the range of the included angle is from 85 degrees to 95 degrees. Further, the included angle is 90 degrees.

[0044] According to the second aspect of the present disclosure, there is also provided a power module, including: the integrated transformer as described in the first aspect.

[0045] In the integrated transformer provided in the embodiments of the present disclosure, by providing two magnetic cores, each magnetic core includes two magnetic yokes and two magnetic columns. The two magnetic yokes are arranged opposite to each other in the first direction; the two magnetic columns are located between the two magnetic yokes and are arranged opposite to each other in the second direction, wherein there is an included angle between the second direction and the first direction, and the included angle is greater than 0 degrees; two short-circuit magnetic blocks, one magnetic yoke in one magnetic core is connected to one magnetic yoke in the other magnetic core through one short-circuit magnetic block to connect the two magnetic cores in series to form a loop; four first windings are provided and are respectively wound around the four magnetic columns of the two magnetic cores as the main transformer; at least one second winding is provided, the second winding is wound around the magnetic core or the short-circuit magnetic block, and the magnetic flux directions generated by the second winding in the two magnetic columns of any magnetic core are the same as the auxiliary transformer. By sharing the magnetic core or providing an auxiliary transformer to use the short-circuit magnetic block for connecting the magnetic cores, the integration of the main transformer and the auxiliary transformer is realized, and the efficiency and power density of the auxiliary transformer are improved; and the main transformer and the auxiliary transformer use independent windings and independent inputs, and the coupling between them is extremely small and they will not interfere with each other.

[0046] It should be understood that the above general description and the following detailed description are only exemplary and explanatory and cannot limit the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] The drawings herein are incorporated into the specification and form a part of the specification, showing embodiments consistent with the present disclosure and, together with the specification, are used to explain the principles of the present disclosure. Obviously, the drawings in the following description are only some embodiments of the present disclosure. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0048] Figure 1 Schematic diagram showing the circuit topology structure in which the SST in the embodiment of the present disclosure converts the medium voltage of 10 kV into a low voltage of 270 V for output;

[0049] Figure 2 Schematic diagram showing a structure of a magnetic core connection of an integrated transformer in the embodiment of the present disclosure;

[0050] Figure 3 Schematic diagram showing a magnetic column in an integrated transformer in the embodiment of the present disclosure;

[0051] Figure 4Shows a structural diagram of another magnetic core connection in an integrated transformer according to an embodiment of the present disclosure;

[0052] Figure 5 Shows a schematic position diagram of an insulation structure in an integrated transformer according to an embodiment of the present disclosure;

[0053] Figure 6 Shows a schematic cross-sectional view of an integrated transformer with an insulation structure according to an embodiment of the present disclosure;

[0054] Figure 7 Shows a schematic structural diagram of an integrated transformer in the first specific example of the present disclosure;

[0055] Figure 8 Shows a schematic structural diagram of an integrated transformer in the second specific example of the present disclosure;

[0056] Figure 9 Shows a schematic structural diagram of an integrated transformer in the third specific example of the present disclosure;

[0057] Figure 10 Shows a schematic structural diagram of another integrated transformer in the third specific example of the present disclosure; and

[0058] Figure 11 Shows a schematic structural diagram of yet another integrated transformer in the third specific example of the present disclosure. Detailed implementation manners

[0059] Now, example embodiments will be described more fully with reference to the accompanying drawings. However, the example embodiments can be implemented in various forms and should not be construed as limited to the examples set forth herein; rather, these embodiments are provided so that this disclosure will be more complete and comprehensive, and will fully convey the concept of the example embodiments to those skilled in the art. The features, structures, or characteristics described may be combined in any suitable manner in one or more embodiments.

[0060] In addition, the accompanying drawings are only schematic illustrations of the present disclosure and are not necessarily drawn to scale. The same reference numerals in the drawings denote the same or similar parts, and thus repeated descriptions thereof will be omitted. Some of the block diagrams shown in the drawings are functional entities and do not necessarily correspond to physically or logically independent entities. These functional entities can be implemented in software form, or in one or more hardware modules or integrated circuits, or in different networks and / or processor devices and / or microcontroller devices.

[0061] The following will describe in detail the specific implementation manners of the embodiments of the present disclosure with reference to the accompanying drawings.

[0062] As Figure 1The figure shows a solution where a medium-voltage solid-state transformer (SST) directly draws power from the distribution network to convert the medium-voltage of 10 kV into a low-voltage output of 270 V. An SST is composed of multiple power modules connected in series and parallel. As shown in the figure, a single power module includes: an AC / DC unit and two DC / DC units with their outputs in parallel. Among them, the transformer (main transformer) of the DC / DC unit undertakes the electrical isolation function between the medium-voltage side (including AC / DC and the primary side of DC / DC) and the low-voltage side (the secondary side of DC / DC) of the main power, and needs to reach the medium-voltage insulation level. In addition to the main power topology, the medium-voltage side and the low-voltage side each require auxiliary circuits such as control circuits, drive circuits, and detection circuits. These circuits all need to be powered by auxiliary power supplies, and the auxiliary power supplies on both the medium-voltage and low-voltage sides also need to achieve the medium-voltage electrical isolation function. Since the auxiliary power supply of the medium-voltage side circuit draws power from the grid-side voltage or the AC / DC bus capacitor, high-voltage-resistant electronic components are required, which increases the complexity and cost of the power supply solution. As shown in the figure, the current auxiliary power supply solution for a single power module is: the auxiliary power supply on the medium-voltage side is obtained by a DC / DC conversion of the auxiliary power supply on the low-voltage side, and the electrical isolation of the auxiliary power supply DC / DC is achieved by an auxiliary power transformer; the auxiliary power supply on the low-voltage side is obtained by converting the 220 V AC mains power at startup and switches to be powered by the 270 V output on the low-voltage side after the main power of the SST starts. Therefore, a single power module of the SST includes two main transformers T1, T2 and an auxiliary transformer T3, and all three transformers need to reach the same medium-voltage isolation level.

[0063] The inventors found that when two main transformers T1, T2 and an auxiliary transformer T3 need to be set in a single power module of the SST, if the auxiliary transformer T3 is set independently, through a separate auxiliary isolation transformer and the circuit of the auxiliary power supply, power is taken from the low-voltage side to provide drive and control power for the medium-voltage side main power circuit. There are many magnetic components in multiple transformers, and there are large volume differences, and the overall structure is relatively messy. At the same time, the efficiency of the auxiliary transformer is low, resulting in a very small power density and large losses of the power module. If the main transformer is set to have multiple outputs and one of the outputs is set as the auxiliary transformer, in this application scenario, the transformer has at least two inputs, one is the medium-voltage of 10 kV on the medium-voltage side, and the other is the 220 V AC mains power. There is a high coupling between the two inputs, interfering with each other.

[0064] To solve the problems of very small power density and large losses of the power module caused by the transformer setting in the above medium-voltage conversion scenario, or high coupling and mutual interference between the inputs, the embodiments of the present disclosure provide an integrated transformer that integrates the main transformer and the auxiliary transformer to improve the power density of the power module and reduce losses. And the inputs between the main transformer and the auxiliary transformer are independent to prevent coupling interference between the two inputs.

[0065] As shown in Figures 2 to 11 the figure, an integrated transformer provided by an embodiment of the present disclosure includes:

[0066] Two magnetic cores 201, each magnetic core 201 includes two magnetic yokes 211 and two magnetic columns 212, and the two magnetic yokes 211 are arranged oppositely along a first direction 213; the two magnetic columns 212 are located between the two magnetic yokes 211, and the two magnetic columns 212 are arranged oppositely along a second direction 214, and there is an included angle between the second direction 214 and the first direction 213; wherein, the included angle is greater than 0 degrees.

[0067] Two short-circuit magnetic blocks 202, one magnetic yoke 211 in one magnetic core 201 is connected to one magnetic yoke 211 in the other magnetic core 201 through one short-circuit magnetic block 202 to connect the two magnetic cores 201 in series to form a loop; it should be noted that the short-circuit magnetic block 202 and the magnetic yoke 211 can be directly connected or indirectly connected, for example, indirectly connected through an air gap to increase leakage magnetic flux.

[0068] Four first windings 203 are respectively wound around the four magnetic columns 212 of the two magnetic cores 201;

[0069] At least one second winding 204, and the second winding 204 is wound around the magnetic core 201 or the short-circuit magnetic block 202. It should be noted that the magnetic flux directions generated by the second winding 204 in the two magnetic columns 212 of any magnetic core 201 are the same.

[0070] By winding the second winding around the magnetic core or the short-circuit magnetic block, the auxiliary transformer and the main transformer share magnetic components, realizing the integration of the auxiliary transformer and the main transformer, so as to reduce the volume and loss of the integrated transformer, thereby improving the power density of the integrated transformer. By separately arranging the first winding and the second winding, the inputs of the auxiliary transformer and the main transformer are independent, and the coupling between the inputs of the auxiliary transformer and the main transformer is extremely small, and the interference is also relatively low.

[0071] It should be noted that, in some embodiments of the present disclosure, the range of the included angle is 85 degrees to 95 degrees, that is, the first direction 213 is substantially perpendicular to the second direction 214. Further, in some embodiments of the present disclosure, the included angle is 90 degrees, and the first direction 213 is perpendicular to the second direction 214. When the first direction 213 is perpendicular to the second direction 214, that is, when the magnetic yoke 211 of the same magnetic core 201 is perpendicular to the magnetic column 212, with the same magnetic core window area, the magnetic path length of the same magnetic core 201 is the shortest, and the volume of the magnetic core 201 is the smallest, where the magnetic core window refers to the space jointly surrounded by the two magnetic yokes 211 and the two magnetic columns 212 of the same magnetic core 201, and the magnetic path length refers to the perimeter of the magnetic core window.

[0072] It should be noted that two first windings 203 wound around two magnetic posts 212 of the same magnetic core 201 form a main transformer. That is, four first windings 203 form two main transformers, and one second winding 204 forms an auxiliary transformer. That is to say, the integrated transformer provided in the embodiments of the present disclosure integrates at least two main transformers and one auxiliary transformer. Those skilled in the art can understand that the number of auxiliary transformers integrated in the integrated transformer is not fixed, that is, the number of second windings 204 is not fixed, and can be one, two, three, etc., which is set according to actual needs and is not limited in the embodiments of the present disclosure.

[0073] In some embodiments of the present disclosure, each first winding 203 includes a first primary winding and a first secondary winding. The first primary windings wound around two magnetic posts 212 of the same magnetic core 201 are connected in series; the first secondary windings wound around two magnetic posts 212 of the same magnetic core 201 are connected in series. Through the series winding method, the induced voltage generated by the magnetic flux of the auxiliary transformer can be in opposite directions on the series-connected first primary windings (or first secondary windings) wound around two magnetic posts 212 of the same magnetic core 201 and can cancel each other out. Further, the number of turns of the first primary windings on two magnetic posts 212 of the same magnetic core 201 is the same, and the number of turns of the first secondary windings on two magnetic posts 212 of the same magnetic core 201 is the same, which can make the induced voltage generated by the magnetic flux of the auxiliary transformer completely cancel out on the series-connected first primary windings wound around two magnetic posts 212 of the same magnetic core 201, and can make the induced voltage generated by the magnetic flux of the auxiliary transformer completely cancel out on the series-connected first secondary windings wound around two magnetic posts 212 of the same magnetic core 201. That is, the induced voltage caused by the auxiliary transformer in each main transformer is 0. The same number of turns of the first primary windings on two magnetic posts 212 of the same magnetic core 201 and the same number of turns of the first secondary windings on two magnetic posts 212 of the same magnetic core 201 mean that the heights of the first primary windings on the two magnetic posts 212 are the same, and the heights of the first secondary windings on the two magnetic posts 212 are also the same, that is, the height of the magnetic core window is utilized to the maximum, so as to realize the decoupling of the main transformer and the auxiliary transformer, avoid the performance degradation or failure caused by the coupling effect between the transformers, and reduce the mutual influence between the main transformer and the auxiliary transformer.

[0074] In some embodiments of the present disclosure, each second winding 204 includes a second primary winding and a second secondary winding. Specifically, in some embodiments of the present disclosure, when the number of the second windings 204 is one, the second winding 204 can be wound around any one of the magnetic cores 201. Correspondingly, the second primary winding and the second secondary winding are concentrically wound around two magnetic posts 212 of any one of the magnetic cores 201. Specifically, in some embodiments of the present disclosure, when the number of the second windings 204 is two, each second winding 204 is wound around two magnetic posts 212 of the same magnetic core 201. It should be noted that the two second windings 204 can be respectively wound around two magnetic cores 201, or can be wound around the same magnetic core 201, and the same magnetic core 201 to be wound can be any one of the two magnetic cores 201. Specifically, in some embodiments of the present disclosure, the second winding 204 can also be wound around the magnetic yoke 211 of the magnetic core 201. When the number of the second windings 204 is one, the second primary winding and the second secondary winding are concentrically wound around any one of the magnetic yokes 211 of any one of the magnetic cores 201. When the number of the second windings 204 is four, one second winding 204 is wound around each of the four magnetic yokes 211 of the two magnetic cores 201, and the second primary winding and the second secondary winding included in each second winding 204 are concentrically wound around the same magnetic yoke 211. Specifically, in some embodiments of the present disclosure, the second winding 204 can be wound around the short-circuit magnetic block 202. When the number of the second windings 204 is one, the second primary winding and the second secondary winding are concentrically wound around any one of the short-circuit magnetic blocks 202. In some embodiments of the present disclosure, the number of the second windings 204 is two; the two second windings 204 are respectively wound around two short-circuit magnetic blocks 202, and the second primary winding and the second secondary winding included in each second winding 204 are concentrically wound around the same short-circuit magnetic block 202.

[0075] In some embodiments of the present disclosure, when the winding positions of the second winding 204 are different, there may be a situation where the auxiliary transformer magnetic flux is unevenly distributed on the two magnetic posts 212 of each magnetic core 201. In this case, the ratio of the exciting magnetic fluxes generated by the second winding 204 in the two magnetic posts 212 of the same magnetic core 201 is the first ratio; the ratio of the number of turns of the first primary winding wound on the two magnetic posts 212 of the same magnetic core 201 is the second ratio; the product of the first ratio and the second ratio is one, so as to ensure that the induced voltage generated by the magnetic flux of the auxiliary transformer can be completely cancelled out on the series-connected first primary windings wound on the two magnetic posts 212 of the same magnetic core 201. And the number of turns of the first secondary winding wound on the same magnetic post 212 of the same magnetic core 201 does not need to be the same as the number of turns of the first primary winding. It only needs to ensure that the ratio of the number of turns of the first secondary winding wound on the two magnetic posts 212 of the same magnetic core 201 is the same as the second ratio, so as to ensure that the induced voltage generated by the magnetic flux of the auxiliary transformer can be completely cancelled out on the series-connected first secondary windings wound on the two magnetic posts 212 of the same magnetic core 201, thereby realizing the decoupling of the main transformer and the auxiliary transformer and reducing the mutual influence between the main transformer and the auxiliary transformer.

[0076] In some embodiments of the present disclosure, an integrated transformer is provided, as Figure 3 shown, each magnetic post 212 is a cuboid, and the magnetic post 212 includes two surfaces connected to the magnetic yoke 211 and four sequentially connected side surfaces; the four side surfaces include two relatively arranged first side surfaces 301 and two relatively arranged second side surfaces 302. The first side surface 301 and the second side surface 302 are connected, the area of the first side surface 301 is larger than that of the second side surface 302, and the first side surface 301 is parallel to the first direction 213 and the first side surface 301 is parallel to the second direction 214; the second side surface 302 is parallel to the first direction 213 and the second side surface 302 is perpendicular to the second direction 214. This will make the structure of each magnetic core 201 including two magnetic posts 212 present a flat shape, which not only makes the volume of the magnetic yoke 211 part in each magnetic core 201 relatively small, reduces the use of magnetic components and lowers the cost; but also makes the composed integrated transformer present a flat shape, occupying a smaller volume, which is not only beneficial to the actual assembly of the power module, but also can improve the power density of the power module. Those skilled in the art can understand that the shape of the magnetic post 212 can also be a cylinder, or a cube, etc., which can be set according to the actual assembly and transformer requirements, and the embodiments of the present disclosure do not make any limitations here.

[0077] In the embodiments of the present disclosure, the two magnetic cores 201 can be connected in a tiled manner or in a stacked manner. Specifically, in some embodiments of the present disclosure, an integrated transformer is provided, and the two magnetic cores 201 are connected in a tiled manner, as Figure 2As shown, two magnetic cores 201 are arranged along the second direction 214. Among them, along the first direction 213, two yokes 211 on the same side of the two magnetic cores 201 are connected by a short-circuit magnetic block 202. In some other embodiments of the present disclosure, an integrated transformer is provided, and the two magnetic cores 201 are connected in a stacked manner. As Figure 4 shown, two magnetic cores 201 are arranged along the third direction 401. It should be noted that the third direction 401 is perpendicular to the first direction 213 and the second direction 214. Among them, along the first direction 213, two yokes 211 on the same side of the two magnetic cores 201 are connected by a short-circuit magnetic block 202.

[0078] It should be noted that in some embodiments of the present disclosure, two short-circuit magnetic blocks 202 are provided between the two yokes 211 of the two magnetic cores 201. As Figure 2 shown, an air gap 221 is provided between the two short-circuit magnetic blocks 202. That is, the yokes 211 on the same side of the two magnetic cores 201 along the first direction 213 are indirectly connected through a short-circuit magnetic block 202, an air gap 221, and a short-circuit magnetic block 202 to increase the leakage magnetic flux. Further, in some embodiments of the present disclosure, the two magnetic cores 201 can be indirectly connected in series into a loop through four short-circuit magnetic blocks 202, and the yokes 211 on the same side of the two magnetic cores 201 along the first direction 213 are both connected by two short-circuit magnetic blocks 202, and an air gap 221 is provided between these two short-circuit magnetic blocks 202.

[0079] In some embodiments of the present disclosure, each short-circuit magnetic block 202 is integrally formed with the adjacent yoke 211 respectively, so that the structure composed of the magnetic core 201 and the short-circuit magnetic block 202 has higher stability and the service life of the integrated transformer is longer; it also makes the preparation of the magnetic components of the integrated transformer simpler, without additional connection processes, and the preparation cost is lower.

[0080] In some embodiments of the present disclosure, the provided integrated transformer, as Figure 5 shown, further includes: an insulating structure 501. Each first winding 203 includes a first primary winding and a first secondary winding. Among them, the insulating structure is used to isolate the first primary winding and the first secondary winding, and to isolate the second primary winding and the second secondary winding. Figure 6 For the Figure 5 cross-sectional view of the integrated transformer obtained from the arrow direction shown as the cross-sectional perspective, Figure 6 the insulating structure adopted in it is solid insulation. It can be seen that the main transformer and the auxiliary transformer share the insulation, and the integrated transformer adopts a common insulation design, so as to streamline the transformer structure, reduce the use of insulating materials, and reduce the manufacturing cost of the integrated transformer on the basis of meeting the insulation requirements. Those skilled in the art can understand that Figure 6The solid insulation in [it] is only for illustration and is represented by a rectangle. In actual application, it may also be bent and will change according to the relative positions between the first winding and the second winding.

[0081] Based on the same inventive concept, an embodiment of the present disclosure also provides a power module as described in the following embodiments. Since the principle of solving problems in this power module embodiment is similar to that of the above integrated transformer embodiment, the implementation of this power module embodiment can refer to the implementation of the above integrated transformer embodiment, and the repeated parts will not be elaborated here.

[0082] In an embodiment of the present disclosure, a power module is further provided, including any one of the integrated transformers as described in the above embodiments. Specifically, the power module may further include a main power supply and an auxiliary power supply for voltage conversion, as well as auxiliary circuits and a voltage conversion unit on both sides of the voltage conversion, such as a DC / DC unit, an AC / DC unit, etc. Those skilled in the art can understand that the power module is used to achieve the medium and low voltage isolation function and voltage adjustment of the main power part and the auxiliary power supply part through the integrated transformer, and the specific structure can be set according to actual needs, and the embodiments of the present disclosure do not limit it here.

[0083] To better illustrate the integrated transformer provided by the embodiments of the present disclosure, several specific examples are given below for further explanation.

[0084] The integrated transformer provided by the first specific example is as Figure 7As shown, two magnetic cores 201 are connected in a tiled manner. The two magnetic cores 201 are arranged along the second direction 214. Along the first direction 213, two yokes 211 on the same side of the two magnetic cores 201 are connected by a short-circuit magnetic block 202. The two magnetic cores 201 are connected in series into a loop through four short-circuit magnetic blocks 202, and an air gap 221 is provided between the two short-circuit magnetic blocks 202 connecting the two yokes 211. Four first windings 203 are respectively wound around four magnetic posts 212 of the two magnetic cores 201. Each first winding 203 includes a first primary winding and a first secondary winding, and the two first primary windings wound around the two magnetic posts 212 of the same magnetic core 201 are connected in series; the two first secondary windings wound around the two magnetic posts 212 of the same magnetic core 201 are connected in series. The number of turns of the first primary windings on the two magnetic posts 212 of the same magnetic core 201 is the same, and the number of turns of the first secondary windings on the two magnetic posts 212 of the same magnetic core 201 is the same, which can make the induced voltage generated by the magnetic flux of the auxiliary transformer completely cancel out on the series-connected first primary windings wound around the two magnetic posts 212 of the same magnetic core 201, and can make the induced voltage generated by the magnetic flux of the auxiliary transformer completely cancel out on the series-connected first secondary windings wound around the two magnetic posts 212 of the same magnetic core 201, that is, the induced voltage caused by the auxiliary transformer in each main transformer is 0. It includes a second winding 204. The second winding 204 is wound around two of the short-circuit magnetic blocks 202. The second primary winding and the second secondary winding included in the second winding 204 are concentrically wound around the two short-circuit magnetic blocks 202, so that the magnetic flux directions generated by the second winding 204 in the two magnetic posts 212 of any magnetic core 201 are the same.

[0085] It should be noted that the size of the short-circuit magnetic block 202 can be set according to actual needs, so that by adjusting the size of the short-circuit magnetic block 202, the effective cross-sectional area of the magnetic element part corresponding to the short-circuit magnetic block 202 and the turn length of the second winding 204 can be adjusted more flexibly. Furthermore, in the scenario where the output voltage of the auxiliary transformer is relatively low, the turn length of the second winding 204 can be reduced to reduce the loss of the auxiliary transformer.

[0086] In this first specific embodiment, the auxiliary transformer formed by the second winding 204 is completely integrated with the main transformer formed by the first winding 203. There is no need to separately set a magnetic core for the auxiliary transformer, which has low cost and relatively simple assembly process, and improves the power density of the power unit; the input between the main transformer and the auxiliary transformer is independent, with extremely small coupling and no mutual interference; due to the symmetry of the structure, the magnetic fluxes of the two main transformers cancel each other out in the corresponding second winding 204 of the auxiliary transformer, and the induced voltage of the magnetic flux of the auxiliary transformer cancels out on the series-connected windings wound around the two magnetic posts 212 corresponding to each main transformer, realizing the decoupling of the auxiliary transformer and the main transformer.

[0087] The integrated transformer provided by the second specific example is as follows Figure 8 As shown, the two magnetic cores 201 are connected in a tiled manner, and the second winding 204 is wound around the yoke 211 portion. Specifically, the two magnetic cores 201 are arranged along the second direction 214. Along the first direction 213, the two yokes 211 on the same side of the two magnetic cores 201 are connected by a short-circuit magnetic block 202, and the two magnetic cores 201 are connected in series into a loop through two short-circuit magnetic blocks 202. Four first windings 203 are respectively wound around the four magnetic posts 212 of the two magnetic cores 201. Each first winding 203 includes a first primary winding and a first secondary winding, and the two first primary windings wound around the two magnetic posts 212 of the same magnetic core 201 are connected in series; the two first secondary windings wound around the two magnetic posts 212 of the same magnetic core 201 are connected in series. The number of turns of the first primary windings on the two magnetic posts 212 of the same magnetic core 201 is the same, and the number of turns of the first secondary windings on the two magnetic posts 212 of the same magnetic core 201 is the same, which can make the induced voltage generated by the magnetic flux of the auxiliary transformer completely cancel out on the series-connected first primary windings wound around the two magnetic posts 212 of the same magnetic core 201, and can make the induced voltage generated by the magnetic flux of the auxiliary transformer completely cancel out on the series-connected first secondary windings wound around the two magnetic posts 212 of the same magnetic core 201, that is, the induced voltage caused by the auxiliary transformer in each main transformer is 0. Figure 8 The integrated transformer shown includes two second windings 204. One second winding 204 is wound around a yoke 211 of one magnetic core 201, and the other second winding 204 is wound around a yoke 211 of the other magnetic core 201, and the two yokes 211 being wound are on the same side, so that the structure of the integrated transformer is symmetrical to make the magnetic flux distribution more uniform. The second primary winding and the second secondary winding included in each second winding 204 are concentrically wound around the yoke 211, so that the excitation magnetic flux directions generated by the second winding 204 in the two magnetic posts 212 of any magnetic core 201 are the same. And it is set that the low-voltage side of the auxiliary transformer is adjacent to the low-voltage side of the main transformer, the high-voltage side of the auxiliary transformer is adjacent to the high-voltage side of the main transformer, and a solid insulation isolation is shared between the auxiliary transformer and the main transformer.

[0088] In this second specific example, the auxiliary transformer and the main transformer share insulation, reducing the cost of achieving insulation between the primary and secondary sides of the auxiliary transformer; multiple (two) second windings are provided, which can meet the output of a larger power or multiple different voltage levels. The auxiliary transformer formed by the second winding 204 is fully integrated with the main transformer formed by the first winding 203, without the need to separately provide a magnetic core for the auxiliary transformer, with low cost and relatively simple assembly process, improving the power density of the power unit; the input between the main transformer and the auxiliary transformer is independent, with extremely small coupling and no mutual interference; due to the symmetry of the structure, the magnetic fluxes of the two main transformers cancel each other out in the corresponding second winding 204 of the auxiliary transformer, and the induced voltage of the magnetic flux of the auxiliary transformer cancels out on the windings connected in series wound around the two magnetic posts 212 corresponding to each main transformer, achieving decoupling between the auxiliary transformer and the main transformer.

[0089] The integrated transformer provided by the third specific example is as Figures 9 to 11 shown, the two magnetic cores 201 are connected in a stacked manner, and the second winding 204 is wound around the magnetic core 201 or the short-circuit magnetic block 202. Specifically, the two magnetic cores 201 are arranged along the third direction 401, and along the first direction 213, the two magnetic yokes 211 on the same side of the two magnetic cores 201 are connected by the short-circuit magnetic block 202. When the two magnetic cores 201 are connected in a stacked manner, the first side surfaces 301 are arranged opposite to each other, so that the structure of the two magnetic cores 201 has the relatively large side surfaces of the magnetic posts facing each other, which can make the magnetic circuit of the integrated transformer more symmetrical and uniform, and also make it easier to achieve decoupling between the main transformer and the auxiliary transformer.

[0090] The integrated transformer provided by the third specific example includes four first windings 203, which are respectively wound around the four magnetic posts 212 of the two magnetic cores 201. Each first winding 203 includes a first primary winding and a first secondary winding, and the two first primary windings wound around the two magnetic posts 212 of the same magnetic core 201 are connected in series; the two first secondary windings wound around the two magnetic posts 212 of the same magnetic core 201 are connected in series. The number of turns of the first primary windings on the two magnetic posts 212 of the same magnetic core 201 is the same, and the number of turns of the first secondary windings on the two magnetic posts 212 of the same magnetic core 201 is the same, which can make the induced voltage generated by the magnetic flux of the auxiliary transformer completely cancel out on the series-connected first primary windings wound around the two magnetic posts 212 of the same magnetic core 201, and can make the induced voltage generated by the magnetic flux of the auxiliary transformer completely cancel out on the series-connected first secondary windings wound around the two magnetic posts 212 of the same magnetic core 201, that is, the induced voltage caused by the auxiliary transformer in each main transformer is 0.

[0091] Figure 9The integrated transformer shown includes two secondary windings 204. One secondary winding 204 is wound around a yoke 211 of a magnetic core 201, and the other secondary winding 204 is wound around a yoke 211 of another magnetic core 201. The two yokes 211 around which the windings are wound are on the same side, so that the structure of the integrated transformer is symmetric, making the magnetic flux distribution more uniform. Each secondary winding 204 includes a secondary primary winding and a secondary secondary winding that are concentrically wound around the same yoke 211, so that the exciting magnetic flux directions generated by the secondary winding 204 in the two magnetic posts 212 of any magnetic core 201 are the same.

[0092] Figure 10 The integrated transformer shown includes four secondary windings 204. The four secondary windings 204 are respectively wound around the four yokes 211 included in the integrated transformer, so that the structure of the integrated transformer is centrosymmetric, and the exciting magnetic flux magnitudes generated by the auxiliary transformers in each magnetic post 212 can be made equal, which is more conducive to decoupling between the two main transformers and between the main transformer and the auxiliary transformers. Each secondary winding 204 includes a secondary primary winding and a secondary secondary winding that are concentrically wound around the same yoke 211, so that the exciting magnetic flux directions generated by the secondary winding 204 in the two magnetic posts 212 of any magnetic core 201 are the same.

[0093] Figure 11 The integrated transformer shown includes a secondary winding 204. The secondary winding 204 is wound around one of the short-circuit magnetic blocks 202. The secondary primary winding and the secondary secondary winding included in the secondary winding 204 are concentrically wound around the short-circuit magnetic block 202, so that the magnetic flux directions generated by the secondary winding 204 in the two magnetic posts 212 of any magnetic core 201 are the same. It should be noted that the size of the short-circuit magnetic block 202 can be set according to actual needs, so that by adjusting the size of the short-circuit magnetic block 202, the effective cross-sectional area of the magnetic element part corresponding to the short-circuit magnetic block 202 and the turn length of the secondary winding 204 can be adjusted more flexibly. Furthermore, in the scenario where the output voltage of the auxiliary transformer is relatively low, the turn length of the secondary winding 204 can be reduced to reduce the loss of the auxiliary transformer.

[0094] In this third specific example, the auxiliary transformer formed by the second winding 204 is fully integrated with the main transformer formed by the first winding 203. There is no need to separately provide a magnetic core for the auxiliary transformer, which results in low cost and relatively simple assembly process, and improves the power density of the power unit. The main transformer and the auxiliary transformer are independently input, with extremely small coupling and no mutual interference. Due to the symmetry of the structure, the magnetic fluxes of the two main transformers cancel each other out in the corresponding second winding 204 of the auxiliary transformer, and the induced voltage of the magnetic flux of the auxiliary transformer cancels out on the windings connected in series wound around the two magnetic posts 212 corresponding to each main transformer, realizing the decoupling of the auxiliary transformer and the main transformer. Moreover, multiple second windings 204 can be provided to meet the output of higher power or multiple different voltage levels.

[0095] For the integrated transformer provided in the fourth specific example, the number of turns of the first primary windings on the two magnetic posts 212 of the same magnetic core 201 is different, and the number of turns of the first secondary windings on the two magnetic posts 212 of the same magnetic core 201 is different. The ratio of the number of turns of the first primary winding wound around the two magnetic posts 212 in the same magnetic core 201 is set as the second ratio, and the ratio of the number of turns of the first secondary winding wound around the two magnetic posts 212 in the same magnetic core 201 is also the second ratio. Among them, the second ratio is the reciprocal of the first ratio, and the first ratio is the ratio of the exciting magnetic fluxes generated by the second winding 204 in the two magnetic posts 212 of the same magnetic core 201. By adjusting the number of turns of the first winding 203, decoupling of the main transformer and the auxiliary transformer is achieved in the case where the distribution of the exciting magnetic fluxes generated by the second winding 204 is inconsistent under different structures of the integrated transformer.

[0096] Assume that the exciting magnetic fluxes generated by the second winding 204 in the first magnetic post and the second magnetic post of the same magnetic core 201 are Фa and Фb, then the ratio of the number of turns Na / Nb of the first primary winding wound around the first magnetic post and the second magnetic post in the magnetic core 201 is Фb / Фa.

[0097] Those skilled in the art can understand that various aspects of the present disclosure can be implemented as a system, a method, or a program product. Therefore, various aspects of the present disclosure can be specifically implemented in the following forms, namely: a complete hardware implementation, a complete software implementation (including firmware, microcode, etc.), or an implementation combining hardware and software aspects, which can be collectively referred to as "circuit", "module", or "system" here. It should be noted that although several modules or units of devices for action execution are mentioned in the above detailed description, this division is not mandatory. In fact, according to the embodiments of the present disclosure, the features and functions of the two or more modules or units described above can be embodied in one module or unit. Conversely, the features and functions of one module or unit described above can be further divided and embodied by multiple modules or units.

[0098] In addition, although the various steps of the methods in this disclosure are described in a specific order in the drawings, this does not require or imply that the steps must be performed in that specific order, or that all of the steps shown must be performed to achieve the desired result. Additionally or alternatively, some steps may be omitted, multiple steps may be combined into one step for execution, and / or one step may be decomposed into multiple steps for execution, etc.

[0099] From the description of the above embodiments, those skilled in the art can easily understand that the exemplary embodiments described herein can be implemented by software, or by a combination of software and necessary hardware. Therefore, the technical solutions according to the embodiments of this disclosure can be embodied in the form of a software product, which can be stored in a non-volatile storage medium (which can be a CD-ROM, a USB flash drive, a mobile hard disk, etc.) or on a network, and includes several instructions to enable a computing device (which can be a personal computer, a server, a mobile terminal, or a network device, etc.) to execute the methods according to the embodiments of this disclosure.

[0100] After considering the specification and practicing the invention disclosed herein, those skilled in the art will readily conceive of other embodiments of this disclosure. This disclosure is intended to cover any variations, uses, or adaptations of this disclosure that follow the general principles of this disclosure and include known common general knowledge or conventional technical means in the technical field not disclosed in this disclosure. The specification and examples are only regarded as exemplary, and the true scope and spirit of this disclosure are pointed out by the appended claims.

Claims

1. An integrated transformer, characterized in that, Comprising: Two magnetic cores, each magnetic core comprising two yokes and two magnetic posts, the two yokes being arranged opposite to each other in a first direction; the two magnetic posts being located between the two yokes, and the two magnetic posts being arranged opposite to each other in a second direction, there being an included angle between the second direction and the first direction, the included angle being greater than 0 degrees; Two short-circuit magnetic blocks, one yoke in one magnetic core being connected to one yoke in the other magnetic core through one short-circuit magnetic block to connect the two magnetic cores in series to form a loop; Four first windings respectively wound around the four magnetic posts of the two magnetic cores; At least one second winding wound around the magnetic core or the short-circuit magnetic block; wherein, the magnetic flux directions generated by the second winding in the two magnetic posts of any one magnetic core are the same.

2. The integrated transformer according to claim 1, wherein, Each first winding comprises a first primary winding and a first secondary winding; The first primary windings wound around the two magnetic posts of the same magnetic core are connected in series; The first secondary windings wound around the two magnetic posts of the same magnetic core are connected in series.

3. The integrated transformer according to claim 2, wherein The number of turns of the first primary windings wound around the two magnetic posts of the same magnetic core is the same, and the number of turns of the first secondary windings wound around the two magnetic posts of the same magnetic core is the same.

4. The integrated transformer according to claim 2, wherein The ratio of the exciting magnetic fluxes generated by the second winding in the two magnetic posts of the same magnetic core is a first ratio; The ratio of the number of turns of the first primary windings wound around the two magnetic posts of the same magnetic core is a second ratio; The product of the first ratio and the second ratio is one; The ratio of the number of turns of the first secondary windings wound around the two magnetic posts of the same magnetic core is the same as the second ratio.

5. The integrated transformer according to claim 1, characterized in that, Each magnetic post is a cuboid, and the magnetic post comprises two surfaces connected to the yoke and four sequentially connected side surfaces; The four side surfaces comprise two relatively arranged first side surfaces and two relatively arranged second side surfaces, the first side surfaces and the second side surfaces being connected, and the area of the first side surfaces being greater than that of the second side surfaces; The first side surfaces are parallel to the first direction and parallel to the second direction; The second side surfaces are parallel to the first direction and perpendicular to the second direction.

6. The integrated transformer according to claim 1, wherein The two magnetic cores are arranged along the second direction; Wherein, along the first direction, the two yokes on the same side of the two magnetic cores are connected through the short-circuit magnetic block.

7. The integrated transformer according to claim 1, wherein The two magnetic cores are arranged along a third direction; The third direction is perpendicular to the first direction and the second direction; Wherein, along the first direction, the two yokes on the same side of the two magnetic cores are connected through the short-circuit magnetic block.

8. The integrated transformer according to claim 1, characterized in that, The second winding comprises a second primary winding and a second secondary winding.

9. The integrated transformer according to claim 8, wherein The second primary winding and the second secondary winding are concentrically wound around the two magnetic posts of any one magnetic core.

10. The integrated transformer according to claim 9, wherein The number of the second windings is two; Each second winding is wound around the two magnetic posts of the same magnetic core.

11. The integrated transformer according to claim 8, wherein, The second primary winding and the second secondary winding are concentrically wound around any one yoke of any one magnetic core.

12. The integrated transformer according to claim 11, wherein, The number of the second windings is four; One of the second windings is wound around each of the four yokes of the two magnetic cores.

13. The integrated transformer according to claim 8, characterized in that, The second primary winding and the second secondary winding are concentrically wound around any one of the short-circuit magnetic blocks.

14. The integrated transformer according to claim 13, wherein The number of the second windings is two; The two second windings are respectively wound around the two short-circuit magnetic blocks.

15. The integrated transformer according to claim 8, characterized in that, It further includes: An insulating structure; Each of the first windings includes a first primary winding and a first secondary winding; Wherein, the insulating structure is used to isolate the first primary winding and the first secondary winding, and to isolate the second primary winding and the second secondary winding.

16. The integrated transformer according to claim 1, wherein, Two short-circuit magnetic blocks are arranged between the two yokes of the two magnetic cores, and an air gap is arranged between the two short-circuit magnetic blocks.

17. The integrated transformer according to claim 16, wherein Each of the short-circuit magnetic blocks is integrally formed with the adjacent yoke.

18. The integrated transformer according to claim 1, characterized in that, The range of the included angle is 85 degrees to 95 degrees.

19. The integrated transformer according to claim 18, wherein The included angle is 90 degrees.

20. A power module, characterized in that, It includes at least one integrated transformer as described in any one of claims 1 to 19.

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