Transformer for vehicle-mounted charger of electric vehicle

Abstract

The present invention relates to a transformer for an on-board charger of an electric vehicle, comprising: a primary coil (110) for receiving power from a charger of an electric vehicle; and a secondary coil (120) that outputs to the high-voltage battery, in which the primary coil (110) is formed by winding a first adhesive-type four-corner wire in the form of a coil and has a first hollow portion (C1), and the secondary coil (120) is formed by winding a second adhesive-type four-corner wire in the form of a coil and has a second hollow portion (C2), and in which the first hollow portion (C1) and the second hollow portion (C2) are formed. The first and second adhesive-type wrapped four-corner conducting wires are copper thin cable four-corner bundles formed by arranging copper thin cables in contact with each other, wherein the copper thin cables are formed by twisting a plurality of copper thin wires (Li), and the whole arrangement is in a four-corner shape. The insulating sheath is wrapped outside the four-corner bundle of the copper thin cable; according to the present invention, an adhesive layer is formed by coating an adhesive on the outer peripheral surface of an insulating sheath, thereby having very excellent face-to-face adhesion.

Description

Technical Field

[0001] The present invention relates to an on-board charger for an electric vehicle. Background Art

[0002] Plug-in hybrid electric vehicles (PHEVs) and electric vehicles (EVs) [hereinafter collectively referred to as electric vehicles] require a charging device that charges a high-voltage battery for driving the vehicle's motor with 200V AC, and this is called an on-board charger.

[0003] In an electric vehicle, the common power (200V AC) supplied through the charger includes: an on-board charger that charges a high-voltage battery for driving the vehicle's motor; a high-voltage battery that charges the power converted from the on-board charger; and an LDC (Low DC-DC Converter) that converts the high voltage of the high-voltage battery into a low voltage of 12V and supplies power to the electrical components of the vehicle.

[0004] Moreover, in the on-board charger installed in the electric vehicle, there are included: a first converter that performs full-wave rectification on the 220V AC supplied through the charger using a bridge rectifier and boosts the voltage of the full-wave rectified voltage through a boost converter circuit; a second converter that converts the rectified voltage output from the first converter into a high-frequency AC voltage through a full-bridge circuit; a transformer that transforms the high-frequency AC voltage output from the second converter into a higher voltage and physically insulates between 220VAC and the high-voltage battery; and a rectifying section that rectifies and filters the high-frequency high-voltage AC voltage transformed by the transformer, converts it into a DC voltage, and supplies it to the high-voltage battery.

[0005] Hereinafter, the configuration of a transformer for an on-board charger according to the prior art will be described.

[0006] The transformer for an on-board charger according to the prior art winds a primary coil around a specially manufactured bobbin, and winds an insulating tape around the wound primary coil for insulation.

[0007] Then, after winding the insulating tape around the primary coil, a secondary coil is wound. After winding the secondary coil, the insulating tape is wound again for insulation. Then, when the winding operation of the secondary coil is performed three times, each time the secondary coil is wound, an insulating tape is wound in the middle for insulation.

[0008] However, the transformer for an on-board charger of the above-mentioned prior art electric vehicle has the following problems.

[0009] First, the size of the transformer product is quite large. The secondary coil is wound coaxially on the primary coil wound on the bobbin, so there is a problem that the size of the product becomes larger, which also makes the overall size of the in-vehicle charger larger.

[0010] Second, the assembly process of winding the primary coil repeatedly and then winding the insulating tape for insulation, and then winding the secondary coil on the insulating tape and winding the insulating tape again is required. Therefore, the assembly process is greatly reduced, and there is a disadvantage of reduced productivity.

[0011] Third, the winding operations of the primary coil and the secondary coil are carried out manually. Therefore, the coils are not aligned during winding, resulting in large losses and reduced EMI performance. Summary of the Invention

[0012] Technical Problems to be Solved by the Invention

[0013] The present invention is provided to solve the above problems of the prior art. The object of the transformer for an in-vehicle charger of an electric vehicle of the present invention is to provide a transformer for an in-vehicle charger of an electric vehicle.

[0014] First, the copper fine wires of the primary and secondary coils are formed in a rectangular shape, and after being covered with an insulating outer skin along their outer surfaces, an adhesive layer is formed on it, so that the first and second adhesive-type covered rectangular wires that are wound face to face and closely adhered to each other are melted and adhered to form a coil shape. Therefore, the close adhesion face to face is very excellent, and thus, compared with the manufacture of conventional wires, the space utilization degree for the same number of coil turns is excellent.

[0015] Second, reduce the volume of the transformer for an in-vehicle charger, and be able to minimize the occupied space in the in-vehicle charger panel.

[0016] Third, the close adhesion face to face is very excellent, and, compared with the manufacture of conventional wires, the space utilization degree for the same number of coil turns is excellent, so that the value of the leakage current can be minimized.

[0017] Fourth, even in the case of a high voltage of several to several tens of kV levels, insulation breakdown will not occur, and the efficiency between the primary coil and the secondary coil can be maintained.

[0018] Fifth, supply a large current and a high voltage in a small size.

[0019] Sixth, a pair of support tubes are formed in the up and down directions with the second disc as the center. Through the pair of support tubes, the first and second magnetic coils, the primary coil, and the secondary coil are all clamped simultaneously, and the first and third chassis support the first and second magnetic coils. The overall module of the transformer is stably assembled with a small number of components without movement or play.

[0020] Seventh, in the structure of the transformer protruding rearward, the back surfaces of the convex portion located at the rearmost, the first rear wing, and the third rear wing are all on the same line, and all form a flat surface. Therefore, when installing the on-vehicle charger transformer of an embodiment of the present invention on a fixed object at the rear, it can be easily and conveniently installed.

[0021] Technical solution for solving the problem

[0022] In order to achieve the above object, the on-vehicle charger transformer of the electric vehicle of the present invention, as an on-vehicle charger (On-Board Charger) that charges the high-voltage battery of the electric vehicle with the commercial alternating current power supplied from the charger of the electric vehicle, includes: a flat primary side coil that receives the power supplied from the charger of the electric vehicle; a flat secondary side coil that generates an induced current by means of the current flowing through the primary side coil and outputs the generated induced current to the high-voltage battery. And, the primary side coil is formed by winding the first adhesive-coated rectangular wire in a coil shape and having a first hollow portion formed in the center. The first adhesive-coated rectangular wire is formed by the following structure: a copper fine wire cable rectangular bundle in which copper fine wire cables made by stranding a plurality of copper fine wires are arranged in contact with each other, and the overall shape of the arrangement is formed in a rectangular shape; an insulating outer skin that covers the outside of the copper fine wire cable rectangular bundle; an adhesive layer that is coated with an adhesive on the outer peripheral surface of the insulating outer skin. The primary side coil is formed by winding the first adhesive-coated rectangular wire in contact with each other face to face multiple times, and then melting and hardening the coated adhesive layer, so that the first adhesive-coated rectangular wires in contact with each other by winding are formed into a coil shape through melting and bonding. The secondary side coil is formed by winding the second adhesive-coated rectangular wire in a coil shape and having a second hollow portion formed in the center. And, the second adhesive-coated rectangular wire is formed by the following structure: a copper fine wire cable rectangular bundle in which copper fine wire cables made by stranding a plurality of copper fine wires are arranged in contact with each other, and the overall shape of the arrangement is formed in a rectangular shape; an insulating outer skin that covers the outside of the copper fine wire cable rectangular bundle; an adhesive layer that is coated with an adhesive on the outer peripheral surface of the insulating outer skin. The secondary side coil is formed by winding the second adhesive-coated rectangular wire in contact with each other face to face multiple times, and then melting and hardening the coated adhesive layer, so that the second adhesive-coated rectangular wires in contact with each other by winding are formed into a coil shape through melting and bonding.

[0023] Effects of the invention

[0024] The on-vehicle charger transformer of the electric vehicle of the present invention having the above structure has the following effects:

[0025] First, the copper fine wires of the primary and secondary coils are shaped in a four-corner form, and after being covered with an insulating outer skin along their outer surfaces, an adhesive layer is formed on the top surface, so that the first and second adhesive-type covered four-corner wires that are wound tightly face to face are fused together to form a coil shape. Therefore, the tightness when facing each other is very excellent. Thus, compared with the manufacture of conventional wires and cables, the space utilization degree for the same number of coil turns is excellent.

[0026] Second, the volume of the transformer for in-vehicle chargers is reduced, and the occupied space in the in-vehicle charger panel can be minimized.

[0027] Third, the tightness when facing each other is very excellent, and compared with the manufacture of conventional wires and cables, the space utilization degree for the same number of coil turns is excellent. Thus, the value of leakage current can be minimized.

[0028] Fourth, even in the case of high voltages in the range of several to dozens of kV, insulation breakdown will not occur, and the efficiency between the primary coil and the secondary coil can be maintained.

[0029] Fifth, a large current and high voltage are supplied in a small size.

[0030] Sixth, a pair of support tubes are formed in the up and down directions with the second disc as the center. Through this pair of support tubes, the first and second magnetic coils, the primary coil, and the secondary coil are all clamped simultaneously. And, the first and third chassis support the first and second magnetic coils. The entire module of the transformer is assembled stably with a small number of components, without movement or play.

[0031] Seventh, in the structure of the transformer protruding backward, the back surfaces of the convex part located at the rearmost, the first rear wing, and the third rear wing are all on the same line, and all form flat surfaces. Therefore, when installing the transformer for in-vehicle chargers of an electric vehicle according to an embodiment of the present invention on a rear fixture, it can be installed easily and conveniently. Brief Description of the Drawings

[0032] Figure 1 is a perspective view of the transformer for in-vehicle chargers of an electric vehicle according to an embodiment of the present invention;

[0033] Figure 2 is an exploded perspective view of the transformer for in-vehicle chargers of an electric vehicle according to an embodiment of the present invention;

[0034] Figure 3 is Figure 2 a bottom perspective view of;

[0035] Figure 4 is Figure 1 a cross-sectional view in the front-rear direction of;

[0036] Figure 5 Cross-sectional view in the front-rear direction of the in-vehicle charger transformer for an electric vehicle according to an embodiment of the present invention, with the first and second magnetic coils 160 and 170 removed;

[0037] Figure 6 Perspective view of the in-vehicle charger transformer for an electric vehicle according to another embodiment of the present invention, with the first and second magnetic coils 160 and 170 removed;

[0038] Figure 7 Conceptual explanatory diagram of the first and second adhesive-type sheathed square wires 110' and 120' forming the primary and secondary coils 110 and 120 in the in-vehicle charger transformer for an electric vehicle according to another embodiment of the present invention;

[0039] Figure 7 (a) of is a conceptual diagram of the first and second adhesive-type sheathed square wires 110' and 120' in a state where the entire insulating outer sheaths 112 and 122 are sheathed;

[0040] Figure 7 (b) of is a conceptual explanatory diagram of the first and second adhesive-type sheathed square wires 110' and 120' in a state where a part of the insulating outer sheaths 112 and 122 is exposed;

[0041] Figure 7 (c) of is a conceptual explanatory diagram of the first and second adhesive-type sheathed square wires 110' and 120' for explaining the adhesive layers 113 and 123;

[0042] Figure 7 (d) of is a conceptual explanatory diagram of the primary and secondary coil copper fine wire cables 111 and 121 of the primary and secondary coils formed by stranding a plurality of copper fine wires Li.

[0043] Explanation of reference numerals

[0044] 110: Primary coil C1: First hollow part

[0045] 110': First adhesive-type sheathed square wire

[0046] 111: Copper fine wire cable of primary coil

[0047] 111': Copper fine wire cable square bundle of primary coil

[0048] 112: Insulating outer sheath 113: Adhesive layer

[0049] 110i: Input part of primary coil 110f: Output part of primary coil

[0050] 120: Secondary coil C2: Second hollow part

[0051] 120': Second adhesive type foreskin square wire

[0052] 121: Copper fine wire cable of the secondary side coil

[0053] 121': Square bundle of copper fine wire cable of the secondary side coil

[0054] 122: Insulating outer skin 123: Adhesive layer

[0055] 120i: Input part of the secondary side coil 120f: Output part of the secondary side coil

[0056] 130: First chassis

[0057] 131: First plate 131a: First central hole

[0058] 132: First support tube 132a: First through hole

[0059] 132b: First insertion protrusion 134: First front wing

[0060] 134a: Central part of the first front wing 134b: Bent part of the first front wing

[0061] 135: First rear wing

[0062] 135a: Central part of the first rear wing 134b: Bent part of the first rear wing

[0063] 135r: Back surface of the first rear wing

[0064] 140: Second chassis 141: Second disc

[0065] 141a: Second central hole 141b: Open port

[0066] 142: Second lower support tube 142a: Second lower through hole

[0067] 142b: Second lower insertion groove 142c: Lower step edge

[0068] 143: Second upper support tube 143a: Second upper through hole

[0069] 143b: Second upper insertion groove 143c: Upper step edge

[0070] 150: Third chassis

[0071] 151: Third plate 151a: Third central hole

[0072] 152: Third support tube 152a: Third through hole

[0073] 152b: Third insertion projection 154: Third front wing

[0074] 154a: Central part of the third front wing 154b: Bent part of the third front wing

[0075] 155: Third rear wing

[0076] 155a: Central part of the third rear wing 154b: Bent part of the third rear wing

[0077] 155r: Back surface of the third rear wing

[0078] 160: First magnetic coil 161: Base part

[0079] 161f: Front surface of the base part 161r: Rear surface of the base part

[0080] 162: Middle foot 163: Outer foot

[0081] 163a: Horizontal face part on the outer surface of the outer foot 163b: Inclined face part on the outer surface of the outer foot

[0082] 170: Second magnetic coil 171: Base part

[0083] 171: Base part

[0084] 171f: Front surface of the base part 171r: Rear surface of the base part

[0085] 172: Middle foot 173: Outer foot

[0086] 173a: Horizontal face part on the outer surface of the outer foot 173b: Inclined face part on the outer surface of the outer foot Detailed implementation mode

[0087] The preferred embodiments of the in-vehicle charger transformer for an electric vehicle of the present invention will be described in detail below with reference to the accompanying drawings.

[0088] Figures 1 to 6 Among them, the primary and secondary coils 110 and 120 formed by the first and second adhesive-coated rectangular wires 110' and 120' are not shown in detail and are only conceptually represented.

[0089] In Figure 7 shown in Figures 1 to 6 the detailed structure of the first and second adhesive-coated rectangular wires 110' and 120' forming the primary and secondary coils 110 and 120 is disclosed.

[0090] The on-vehicle charger transformer for an electric vehicle according to an embodiment of the present invention, as an on-vehicle charger for an electric vehicle that charges a high-voltage battery (not shown) of the electric vehicle with commercial AC power (220VAC) supplied from a charger (not shown) of the electric vehicle, includes: a flat primary coil 110 that receives power supply from the charger of the electric vehicle; and a flat secondary coil 120 that generates an induced current through the current flowing in the primary coil 110 and outputs the generated induced current to the high-voltage battery.

[0091] Here, the primary coil 110 is formed by winding the first adhesive-coated rectangular wire 110' in a coil shape, and a first hollow portion C1 is formed in the center.

[0092] The first adhesive-coated rectangular wire 110' is formed by arranging copper fine wire cables 111 made by stranding a plurality of copper fine wires (Li) in contact with each other, and the overall shape of the arrangement is composed of a copper fine wire cable rectangular bundle 111' formed in a rectangular shape and an insulating outer skin 112 covering the outer surface of the copper fine wire cable rectangular bundle 111'; and an adhesive layer 113 coated on the outer peripheral surface of the insulating outer skin 112.

[0093] At this time, the primary coil 110 is formed by using a winding member (not shown) to wind the first adhesive-coated rectangular wire 110' in close contact with each other face to face multiple times, and then melting the coated adhesive layer 113 with a solvent (for example, alcohol) or supplying heat (or hot air) to melt and harden it, so that the first adhesive-coated rectangular wire 110' wound in close contact with each other is welded and bonded to each other to form a coil shape.

[0094] And the secondary coil 120 is formed by winding the second adhesive-coated rectangular wire 120' in a coil shape, and a second hollow portion C2 is formed in the center.

[0095] The second adhesive-coated rectangular wire 120' is formed by arranging copper fine wire cables 121 made by stranding a plurality of copper fine wires (Li) in contact with each other, and the overall shape of the arrangement is a copper fine wire cable rectangular bundle 121' formed in a rectangular shape; an insulating outer skin 122 covering the outer surface of the copper fine wire cable rectangular bundle 121'; and an adhesive layer 123 coated on the outer peripheral surface of the insulating outer skin 122.

[0096] Here, the secondary coil 120 is formed by using a winding component (not shown) to wind the second adhesive-coated square wire 120' tightly around each other face to face, and then melting or supplying heat (or hot air) to melt the coated adhesive layer 123 and hardening it, so that the second adhesive-coated square wires 120' wound tightly around each other face to face are welded and bonded together to form a coil shape.

[0097] As described above, the copper fine wires 111 and 121 of the primary and secondary coils 110 and 120 are formed into a square shape, and are covered with insulating sheaths 112 and 122 along their outer surfaces, and adhesive layers 113 and 123 are formed on them, so that the first and second adhesive-coated square wires 110' and 120' wound tightly around each other face to face are welded and bonded together to form a coil shape. Therefore, the face-to-face tightness is very excellent, and compared with the manufacture of conventional wires and cables, the space utilization degree is excellent compared with the same number of coil turns. Therefore, the volume of the transformer for in-vehicle chargers can be reduced, and there is a benefit of reducing the occupied space in the main PCB (Printed Circuit Board) (not shown) of the in-vehicle charger.

[0098] Furthermore, there are the following benefits: the face-to-face tightness is very excellent, and compared with the manufacture of conventional wires and cables, the space utilization degree is excellent compared with the same number of coil turns, so that the value of the leakage current can be minimized.

[0099] Moreover, even under high voltages in the range of several to dozens of kV, insulation breakdown does not occur, and the efficiency between the primary coil 110 and the secondary coil 120 can still be maintained.

[0100] And, according to the overall structure of the primary coil 110 and the secondary coil 120 as described above, a large current and a high voltage can be supplied in a small size.

[0101] And, as described above, the primary coil 110 and the secondary coil 120 of the transformer for in-vehicle chargers are welded together by themselves, so that the tightness of the primary coil 110 and the secondary coil 120 of the transformer for in-vehicle chargers can be improved, and the tightness between the primary coil 110 and the secondary coil 120 is also relatively high. Thus, losses can be reduced, the efficiency can be further improved, and while the height of the transformer is further reduced (it can be miniaturized by 70% compared with the conventional in-vehicle charger transformer), the size of the transformer is made more miniaturized (it can be miniaturized by 70% compared with the conventional in-vehicle charger transformer).

[0102] Moreover, it can reduce the height of the transformer for in-vehicle chargers and shrink the size of the product. Therefore, it can reduce the size of the in-vehicle charger itself, thereby reducing the occupied space in the electric vehicle and achieving weight reduction, thus enhancing the product competitiveness of the in-vehicle charger in the electric vehicle.

[0103] Moreover, as described above, the primary coil 110 and the secondary coil 120 of the transformer for in-vehicle chargers can be manufactured using a coil clamp or a winder. Therefore, it can automate the production of the primary coil 110 and the secondary coil 120 of the transformer for in-vehicle chargers, thereby reducing the assembly process (the assembly process can be reduced by 50% compared to the production process of the conventional in-vehicle charger transformer), significantly improving productivity, and thus enhancing price competitiveness.

[0104] The winding component can use a coil clamp or a winder.

[0105] The adhesive can be formed by an adhesive coating.

[0106] The copper fine wire cable quadruplet 111' forming the first adhesive-type covered quadruplet wire 110' is formed by arranging the copper fine wire cables 111 closely in the up-down and left-right directions (array) to form a quadrilateral shape.

[0107] Similarly, the copper fine wire cable quadruplet 121' forming the second adhesive-type covered quadruplet wire 120' is formed by arranging the copper fine wire cables 121 closely in the up-down and left-right directions (array) to form a quadrilateral shape.

[0108] Here, the quadrilateral shape of the copper fine wire cable quadruplets 111', 121' forms a square as shown in the attached drawings, or can be formed as a rectangle according to the embodiments.

[0109] The quadrilateral shape of the copper fine wire cable quadruplets 111', 121' of the first and second adhesive-type covered quadruplet wires 110', 120' can be formed by passing through a quadruplet roller capable of forming a quadrilateral shape.

[0110] The input part 110i and the output part 110f of the primary coil 110 are connected to the charger side of the electric vehicle, and the input part 120i and the output part 120f of the secondary coil 120 are connected to the charger side of the electric vehicle.

[0111] The input part 110i and the output part 110f of the primary coil 110 are all wound and arranged towards the charger side of the electric vehicle in the same direction, and the input part 120i and the output part 120f of the secondary coil 120 are all wound and arranged in the same direction.

[0112] Thus, both the primary coil 110 and the secondary coil 120 of the in-vehicle charger transformer are formed in a flat plate type and are housed in one housing. Thereby, the height of the product of the in-vehicle charger transformer can be reduced, and the size of the product can be reduced.

[0113] Moreover, it is possible to reduce the loss between the primary coil and the secondary coil in the in-vehicle charger of the electric vehicle and improve the efficiency.

[0114] Moreover, the insulating sheaths 112 and 122 are formed of insulating tapes.

[0115] The insulating tape is formed of, for example, a polyimide tape.

[0116] The in-vehicle charger transformer of an embodiment of the present invention for an electric vehicle further includes: a first magnetic coil 160 inserted into a first hollow portion C1 of the primary coil 110; a second magnetic coil 170 inserted from above the first magnetic coil 160 into a second hollow portion C2 of the secondary coil 120 to form a closed magnetic flux with the first magnetic coil 160; a first base frame 130 inserted into the first magnetic coil 160 and capable of clamping the primary coil 110; a second base frame 140 inserted and fixed to the primary coil 110 fixed to the first base frame 130 and maintaining an insulating distance between the primary coil 110 and the secondary coil 120 for insulation; and a third base frame 150 inserted and fixed to the secondary coil 120 inserted and fixed to the second base frame 140.

[0117] The first magnetic coil 160 includes a flat base portion 161; a middle leg 162 protruding from the center of the base portion 161 toward the primary coil 110 and inserted into the first hollow portion C1 of the primary coil 110; and a pair of outer legs 163 separated from the middle leg 162 and protruding from the outside of the base portion 161 toward the primary coil 110.

[0118] The second magnetic coil 170 includes a flat base portion 171; a middle leg 172 protruding from the center of the base portion 171 toward the secondary coil 120 and inserted into the second hollow portion C2 of the secondary coil 120; and a pair of outer legs 173 separated from the middle leg 172 and protruding from the outside of the base portion 171 toward the secondary coil 120.

[0119] The first chassis 130 includes: a first plate 131 having a thin plate shape with a first central hole 131a formed in the center; a first through hole 132a formed to communicate with the first central hole 131a of the first plate 131, capable of being inserted into the first hollow portion C1 of the primary side coil 110, and a circular tubular first support tube 132 that protrudes from the first central hole 131a toward the primary side coil 110 to support the primary side coil 110; a first front wing 134 that protrudes from the front edge of the first plate 131 toward the first magnetic coil 160 and is in close contact with the front surface 161f and the outer foot of the first base portion 161 of the first magnetic coil 160 at the same time, capable of preventing play or movement of the first chassis 130; a first rear wing 135 that protrudes from the rear edge of the first plate 131 toward the first magnetic coil 160 and is in close contact with the rear surface 161r and the outer foot 163 of the first base portion 161 of the first magnetic coil 160 at the same time, capable of preventing play or movement of the first chassis 130.

[0120] And the second chassis 140 includes: a second disk 141 having a circular flat plate shape with a second central hole 141a formed in the center; a second lower through hole 142a formed to communicate with the second central hole 141a of the second disk 141, capable of being inserted into the first hollow portion C1 of the primary side coil 110, and a circular tubular second lower support tube 142 that protrudes from the second central hole 141a toward the primary side coil 110 and is axially arranged with a part of the first support tube 132 of the first chassis 130 [a part of the first support tube 132 and the second lower support tube 142 overlap to cross in the height direction (axial direction)], and supports the upper side of the primary side coil 110 at the same time; a second upper through hole 143a formed to communicate with the second central hole 141a of the second disk 141, capable of being inserted into the second hollow portion C2 of the secondary side coil 120, and a circular tubular second upper support tube 143 that protrudes from the second central hole 141a toward the secondary side coil 120 and is axially arranged with a part of the third support tube 152 of the third chassis 150 [a part of the third support tube 152 and the second upper support tube 143 overlap to cross in the height direction (axial direction)], and supports the lower side of the secondary side coil 120 at the same time.

[0121] Further, the third chassis 150 includes: a third plate 151 in a thin plate shape with a third central hole 151a formed in the center; a third through hole 152a formed to communicate with the third central hole 151a of the third plate 151, capable of being inserted into the second hollow portion C2 of the secondary side coil 120, and protruding from the third central hole 151a toward the secondary side coil 120 side, and axially disposed with a part of the second upper support tube 143 of the second chassis 140 [a part of the third support tube 152 and the second upper support tube 143 are stacked to cross in the height direction], and at the same time, a circular tubular third support tube 152 that supports the upper side of the secondary side coil 120; a third front wing 154 that protrudes from the front edge of the third plate 151 toward the second magnetic coil 170 side, and is in close contact with the front surface 171f and the outer foot 173 of the second base portion 171 of the second magnetic coil 170 at the same time, capable of preventing play or movement of the third chassis 150; a third rear wing 155 that protrudes from the rear edge of the third plate 151 toward the second magnetic coil 170 side, and is in close contact with the rear surface 171r and the outer foot 173 of the second base portion 171 of the second magnetic coil 170 at the same time, capable of preventing play or movement of the second chassis 140.

[0122] The primary side coil 110 is placed in the height direction on the first plate 131, inserted between the first plate 131 and the second disc 141, and at the same time, in the radial direction, the first hollow portion C1 is externally inserted into the first support tube 132 and the second lower support tube 142 at the same time and is inserted and fixed.

[0123] The secondary side coil 120 is placed in the height direction on the second disc 141, inserted between the second disc 141 and the third plate 151, and at the same time, in the radial direction, the second hollow portion C2 is externally inserted into the third support tube 152 and the second upper support tube 143 at the same time, and is inserted and fixed.

[0124] The first magnetic coil 160 is inserted into the first support tube 132 and the second lower support tube 142 axially arranged with the middle feet 162 below the first chassis 130 [i.e., in the opposite direction of the primary side coil 110], and thus is inserted into the first hollow portion C1 of the primary side coil 110.

[0125] The second magnetic coil 170 is inserted into the third support tube 152 and the second upper support tube 143 axially arranged with the middle feet 172 above the second chassis 140 [i.e., in the opposite direction of the secondary side coil 120], and thus is inserted into the second hollow portion C2 of the secondary side coil 120.

[0126] As described above, with the second disk 141 as the center, a pair of support tubes 142 and 143 are formed in the vertical direction. And through this pair of support tubes 142 and 143, the first and second magnetic coils 160 and 170, the primary coil 110, and the secondary coil 120 are all supported simultaneously. Moreover, by means of the first and third chassis 130 and 150 to support the first and second magnetic coils 160 and 170, even with a relatively small number of components as a whole, the entire transformer module can be stably assembled without movement or play.

[0127] The first plate 131 of the first chassis 130 is a circular plate shape that matches the primary coil 110. The third plate 151 of the third chassis 150 is a circular plate shape that matches the secondary coil 120. The second disk 141 of the second chassis 140 is a circular disk shape that matches the primary and secondary coils 110 and 120.

[0128] The first front wing 134 of the first chassis 130 includes: a first front wing central portion 134a that protrudes from the front edge of the first plate 131 toward the first magnetic coil 160 and can be in close contact with the center of the front surface 161f of the base portion 161 of the first magnetic coil 160; a first front wing bent portion 134b that extends symmetrically from the first front wing central portion 134a and is in close contact with the outer surface and outer feet 163 of the front surface 161f of the base portion 161 of the first magnetic coil 160 at the same time.

[0129] Similarly, the first rear wing 135 of the first chassis 130 includes: a first rear wing central portion 135a that protrudes from the rear edge of the first plate 131 toward the first magnetic coil 160 and is in close contact with the center of the rear surface 161r of the base portion 161 of the first magnetic coil 160; a first rear wing bent portion 135b that extends symmetrically from the rear wing central portion 135a and is in close contact with the outer surface and outer feet 163 of the rear surface 161r of the base portion 161 of the first magnetic coil 160 at the same time.

[0130] The outer surface of the outer feet 163 of the first magnetic coil 160 is composed of a central horizontal surface portion 163a; and a pair of inclined surface portions 163b that are symmetrically formed from the horizontal surface portion 163a in the inward direction toward the side where the middle feet 162 are formed.

[0131] The first front wing bent portion 134b is formed to be recessed and bent inward, and is in close contact with the front surface 161f of the base 161 of the first magnetic coil 160 and the inclined surface portion 163b of the outer feet 163 at the same time.

[0132] Similarly, the first rear wing bending portion 135b is formed to be bent inwardly recessed, and is simultaneously in close contact with the rear surface 161r of the base 161 of the first magnetic coil 160 and the inclined surface portion 163b of the outer leg 163.

[0133] Moreover, the third front wing 154 of the third chassis 150 includes: a third front wing central portion 154a that protrudes from the front edge of the third plate 151 toward the second magnetic coil 170 side and can be in close contact with the center of the front surface 171f of the base portion 171 of the second magnetic coil 170; and third front wing bending portions 154b that extend symmetrically to the left and right from the third front wing central portion 154a and are simultaneously in close contact with the outer surface and the outer legs 173 of the front surface 171f of the base portion 171 of the second magnetic coil 170.

[0134] Similarly, the third rear wing 155 of the third chassis 150 includes: a third rear wing central portion 155a that protrudes from the rear edge of the third plate 151 toward the second magnetic coil 170 side and is in close contact with the center of the rear surface 171r of the base portion 171 of the second magnetic coil 170; and third rear wing bending portions 155b that extend symmetrically to the left and right from the rear wing central portion 155a and are simultaneously in close contact with the outer surface and the outer legs 173 of the rear surface 171r of the base portion 171 of the second magnetic coil 170.

[0135] The outer surface of the outer leg 173 of the second magnetic coil 170 is composed of a central horizontal surface portion 173a; and a pair of inclined surface portions 173b that are symmetrically formed to be inclined inwardly from the horizontal surface portion 173a toward the side where the middle leg 172 is formed.

[0136] The third front wing bending portion 154b is formed to be bent inwardly recessed so as to be simultaneously in close contact with the front surface 171f of the base 171 of the second magnetic coil 170 and the inclined surface portion 173b of the outer leg 173, and the third rear wing bending portion 155b is formed to be bent inwardly recessed so as to be simultaneously in close contact with the rear surface 171r of the base 171 of the second magnetic coil 170 and the inclined surface portion 173b of the outer leg 173.

[0137] A lower stepped edge 142c is formed on the outer peripheral surface of the second lower support tube 142, and an upper stepped edge 143c is formed on the outer peripheral surface of the second upper support tube 143.

[0138] The lower stepped edge 142c of the second lower support tube 142 is stepped and supported at the upper end of the first support tube 132, so that the first support tube 132 and the second lower support tube 142 can be coaxially arranged in an overlapping manner. Moreover, in the state where the first support tube 132 and the second lower support tube 142 are coaxially arranged in an overlapping manner, the outer peripheral surfaces of the first support tube 132 and the second lower support tube 142 form the same plane.

[0139] The lower end of the third support tube 152 is stepped and supported by the upper stepped edge 143c of the second upper support tube 143, so that the second upper support tube 143 and the third support tube 152 can be coaxially arranged in an overlapping manner. Moreover, in the state where the second upper support tube 143 and the third support tube 152 are coaxially arranged in an overlapping manner, the outer peripheral surfaces of the third support tube 152 and the second upper support tube 143 form the same plane.

[0140] Moreover, a plurality of second lower insertion grooves 142b are formed at equal intervals and recessed in the outer peripheral edge of the second lower support tube 142, and first insertion protrusions 132b that are inserted and engaged with the second lower insertion grooves 142b are formed on the inner peripheral surface of the first support tube 132 of the first chassis 130.

[0141] Moreover, a plurality of second upper insertion grooves 143b are formed at equal intervals and recessed in the outer peripheral edge of the second upper support tube 143, and third insertion protrusions 152b that are inserted and engaged with the second upper insertion grooves 143b are formed on the inner peripheral surface of the third support tube 152 of the third chassis 150.

[0142] Thus, through the organic connection relationship of the magnetic coils 160, 170 -> the first and third chassis 130, 150 -> the second chassis 140, movement and play can be integrally prevented, and stable connection can be achieved.

[0143] In a transformer for an on-vehicle charger of an electric vehicle according to an embodiment of the present invention, it includes: a protruding portion 145 that protrudes rearward from the rear surface of the second disc 141 and has a flat surface on its back surface 145r.

[0144] The back surface 135r of the first rear wing 135 is a flat surface, the back surface 155r of the third rear wing 155 is a flat surface, and the back surface 145r of the protruding portion 145, the back surface 135r of the first rear wing 135, and the back surface 155r of the third rear wing 155 are all formed in the same vertical plane.

[0145] In the configuration of the transformer protruding rearward, the rear surface 145r of the convex portion 145 located at the rearmost, the rear surface 135r of the first rear wing 135, and the rear surface 155r of the third rear wing 155 are all formed in the same vertical plane and all form flat surfaces. Therefore, when installing the in-vehicle charger transformer of an electric vehicle according to an embodiment of the present invention on a rear fixture, it can be easily and conveniently installed.

[0146] A plurality of heat dissipation holes 141b are formed through the second disk 141 in the vertical direction. Thus, it has the benefit of being able to quickly discharge the heat generated from the transformer.

[0147] And, as Figure 6 shown, in the in-vehicle charger transformer of an electric vehicle according to another embodiment of the present invention, an opening 141b that opens outward is formed in the radial inward direction on the outer peripheral surface of the second disk 141.

[0148] With the above-described configuration of the opening 141b, not only can the heat dissipation efficiency be improved, but it is also easy to inject heat dissipation resin for heat dissipation from the outside to the inside.

[0149] In the in-vehicle charger transformer of an electric vehicle according to an embodiment of the present invention, by adjusting the thickness t2 of the second disk 141, the insulation distance between the primary coil 110 and the secondary coil 120 can be adjusted.

[0150] And, preferably, in order to maintain the insulation distance, the thickness t2 of the second disk 141 is thicker than the thicknesses of the first and third plates.

[0151] More preferably, the thickness t2 of the second disk 141 is 3 to 5 times the thicknesses of the first and third plates.

[0152] As described above for the preferred embodiments of the present invention, those of ordinary skill in the technical field of the present invention should understand that it can be implemented in other detailed forms without changing the technical idea or essential features of the present invention except for the embodiments described above. Therefore, the above embodiments are not restrictive but exemplary.

[0153] The scope of the present invention is represented by the claims, rather than the above detailed description, and all changes or variations derived from the meaning and scope of the claims and their equivalent concepts belong to the scope of the present invention.

Claims

1. A transformer for an on-board charger of an electric vehicle, which is an on-board charger of an electric vehicle that charges a high-voltage battery of an electric vehicle with commercial AC power supplied from a charger of the electric vehicle, characterized in that Comprising: A flat primary coil (110) that receives power supplied from a charger of an electric vehicle; A flat secondary coil (120) that generates an induced current by means of the current flowing through the primary coil (110) and outputs the generated induced current to the high-voltage battery, And, the primary coil (110) is formed by winding a first adhesive-coated rectangular wire (110') in a coil shape and having a first hollow portion (C1) formed in the center, The first adhesive-coated rectangular wire (110') is formed of the following structure: A copper fine wire cable rectangular bundle (111'), which arranges copper fine wire cables (111) made by stranding a plurality of copper fine wires (Li) in contact with each other, and the overall shape of the arrangement is formed in a rectangular shape; An insulating outer skin (112) that coats the outside of the copper fine wire cable rectangular bundle (111'); An adhesive layer (113) that coats an adhesive on the outer peripheral surface of the insulating outer skin (112), The primary coil (110) is After winding the first adhesive-coated rectangular wires (110') face-to-face and tightly against each other multiple times, the applied adhesive layer (113) is melted and hardened, so that the first adhesive-coated rectangular wires (110') that are tightly wound against each other form a coil shape through melt bonding between them, The secondary coil (120) is formed by winding a second adhesive-coated rectangular wire (120') in a coil shape and having a second hollow portion (C) formed in the center, And, the second adhesive-coated rectangular wire (120') is formed of the following structure: A copper fine wire cable rectangular bundle (121'), which arranges copper fine wire cables (121) made by stranding a plurality of copper fine wires (Li) in contact with each other, and the overall shape of the arrangement is formed in a rectangular shape; An insulating outer skin (122) that coats the outside of the copper fine wire cable rectangular bundle (121'); An adhesive layer (123) that coats an adhesive on the outer peripheral surface of the insulating outer skin (122), The secondary coil (120) is After winding the second adhesive-coated rectangular wires (120') face-to-face and tightly against each other multiple times, the applied adhesive layer (123) is melted and hardened, so that the second adhesive-coated rectangular wires (120') that are tightly wound against each other form a coil shape through melt bonding between them.

2. The in-vehicle charger transformer for an electric vehicle according to claim 1, characterized in that The copper fine wire cable rectangular bundle (111') forming the first adhesive-coated rectangular wire (110') forms a rectangular shape by arranging the copper fine wire cables (111) tightly against each other vertically and horizontally (array), The copper fine wire cable rectangular bundle (121') forming the second adhesive-coated rectangular wire (120') forms a rectangular shape by arranging the copper fine wire cables (121) tightly against each other vertically and horizontally (array).

3. The transformer for an on-vehicle charger of an electric vehicle according to claim 1, wherein Further comprising: A first magnetic coil (160) that is inserted into the first hollow portion (C1) of the primary coil (110); The second magnetic coil (170) is inserted into the second hollow portion (C2) of the secondary coil (120) from above the first magnetic coil (160) to form a closed magnetic flux with the first magnetic coil (160). The first chassis (130) is inserted into the first magnetic coil (160) and can clamp the primary coil (110). The second chassis (140) is inserted and fixed into the primary coil (110) fixed to the first chassis (130), and can maintain the insulation distance and insulation between the primary coil (110) and the secondary coil (120). The third chassis (150) is inserted and fixed into the secondary coil (120) inserted and fixed to the second chassis (140).

4. The on-vehicle charger transformer for an electric vehicle according to claim 3, characterized in that The first magnetic coil (160) is formed of the following structure: A flat base portion (161); A middle foot (162) that protrudes from the center of the base portion (161) toward the primary coil (110) and is inserted into the first hollow portion (C1) of the primary coil (110); A pair of outer feet (163) that are separated from the middle foot (162) and protrude from the outside of the base portion (161) toward the primary coil (110), The second magnetic coil (170) is formed of the following structure: A flat base portion (171); A middle foot (172) that protrudes from the center of the base portion (171) toward the secondary coil (120) and is inserted into the second hollow portion (C2) of the secondary coil (120); A pair of outer feet (173) that are separated from the middle foot (172) and protrude from the outside of the base portion (171) toward the secondary coil (120), The first chassis (130) is formed of the following structure: The first plate (131) has a thin flat shape with a first central hole (131a) formed in the center; A circular tubular first support tube (132) is formed with a first through hole (132a) communicating with the first central hole (131a) of the first plate (131) and capable of being inserted into the first hollow portion (C1) of the primary coil (110), and protrudes from the first central hole (131a) toward the primary coil (110) to support the primary coil (110); The first front wing (134) protrudes from the front edge of the first plate (131) toward the first magnetic coil (160) and is in close contact with the front surface (161f) and the outer feet (163) of the first base portion (161) of the first magnetic coil (160) at the same time, and can prevent the play or movement of the first chassis (130); The first rear wing (135) protrudes from the rear edge of the first plate (131) toward the first magnetic coil (160) and is in close contact with the rear surface (161r) and the outer feet (163) of the first base portion (161) of the first magnetic coil (160) at the same time, and can prevent the play or movement of the first chassis (130), The second chassis (140) is formed of the following structure: A second disk (141) in the shape of a circular flat plate, which has a second central hole (141a) formed at the center thereof; A lower support tube (142) in the shape of a circular tube, which has a second lower through hole (142a) formed therein and communicating with the second central hole (141a) of the second disk (141) and capable of being inserted into the first hollow portion (C1) of the primary-side coil (110), and protrudes from the second central hole (141a) toward the primary-side coil (110) side, so that a part of the second lower support tube (142) is coaxially arranged with the first support tube (132) of the first chassis (130) and supports the primary-side coil (110) at the same time; A second upper support tube (143) in the shape of a circular tube, which has a second upper through hole (143a) formed therein and communicating with the second central hole (141a) of the second disk (141) and capable of being inserted into the second hollow portion (C2) of the secondary-side coil (120), and protrudes from the second central hole (141a) toward the secondary-side coil (120) side, so that a part of the second upper support tube (143) is coaxially arranged with the third support tube (152) of the third chassis (150) and supports the secondary-side coil (120) at the same time; The third chassis (150) includes the following structure: A third plate (151) in the shape of a thin flat plate, which has a third central hole (151a) formed at the center thereof; A third support tube (152) in the shape of a circular tube, which has a third through hole (152a) formed therein and communicating with the third central hole (151a) of the third plate (151) and capable of being inserted into the second hollow portion (C2) of the secondary-side coil (120), and protrudes from the third central hole (151a) toward the secondary-side coil (120) side, and a part of the third support tube (152) is coaxially arranged with the second upper support tube (143) of the second chassis (140) and supports the secondary-side coil (120) at the same time; A third front wing (154), which protrudes from the front edge of the third plate (151) toward the second magnetic coil (170) side and is in close contact with the front surface (171f) and the outer foot of the second base portion (171) of the second magnetic coil (170) at the same time, and can prevent the play or movement of the third chassis (150); A third rear wing (155), which protrudes from the rear edge of the third plate (151) toward the second magnetic coil (170) side and is in close contact with the rear surface (171r) and the outer foot (173) of the second base portion (171) of the second magnetic coil (170) at the same time, and can prevent the play or movement of the second chassis (140); And, the primary-side coil (110) is placed in the height direction on the first plate (131), inserted between the first plate (131) and the second disk (141), and at the same time, in the radial direction, the first hollow portion (C1) is inserted and fixed outside the first support tube (132) and the second lower support tube (142) at the same time; The secondary coil (120) is placed in the second disc (141) in the height direction, inserted between the second disc (141) and the third plate (151), and at the same time, in the radial direction, the second hollow portion (C2) is externally inserted into the third support tube (152) and the second upper support tube (143) and inserted and fixed. The first magnetic coil (160) is inserted into the first support tube (132) and the second lower support tube (142) which are axially arranged with each other from the lower middle foot (162) of the first chassis (130), so that it can be inserted into the first hollow portion (C1) of the primary coil (110). The second magnetic coil (170) is inserted into the third support tube (152) and the second upper support tube (143) which are axially arranged with each other from the upper middle foot (172) of the second chassis (140), so that it can be inserted into the second hollow portion (C2) of the secondary coil (120).

5. The in-vehicle charger transformer for an electric vehicle according to claim 4, characterized in that The first plate (131) of the first chassis (130) is in a circular plate shape and can be mated with the primary coil (110). The third plate (151) of the third chassis (150) is in a circular plate shape and can be mated with the secondary coil (120). The second disc (141) of the second chassis (140) is in a circular disc shape and can be mated with the primary and secondary coils (110, 120).

6. The in-vehicle charger transformer for an electric vehicle according to claim 5, characterized in that The first front wing (134) of the first chassis (130) is formed with the following structure: The first front wing central part (134a) projects from the front edge of the first plate (131) toward the first magnetic coil (160) side and can be closely attached to the center of the front surface (161f) of the base part (161) of the first magnetic coil (160). The first front wing bending part (134b) extends symmetrically to the left and right from the first front wing central part (134a) and is simultaneously closely attached to the outer surface and the outer foot (162) of the front surface (161f) of the base part (161) of the first magnetic coil (160). The first rear wing (135) of the first chassis (130) is formed with the following structure: The first rear wing central part (135a) projects from the rear edge of the first plate (131) toward the first magnetic coil (160) side and can be closely attached to the center of the rear surface (161r) of the base part (161) of the first magnetic coil (160). The first rear wing bending part (135b) extends symmetrically to the left and right from the rear wing central part (135a) and can be simultaneously closely attached to the outer surface and the outer foot (162) of the rear surface (161r) of the base part (161) of the first magnetic coil (160). The outer surface of the outer foot (163) of the first magnetic coil (160) is formed with the following structure: The central horizontal surface part (163a); A pair of inclined faces (163b) are symmetrically and inwardly inclined from the horizontal face (163a). The first front wing bending part (134b) is bent inwardly and recessedly so as to be in close contact with the front face (161f) of the base part (161) of the first magnetic coil (160) and the inclined face (163b) of the outer foot (163) simultaneously. The first rear wing bending part (135b) is bent inwardly and recessedly so as to be in close contact with the rear face (161r) of the base part (161) and the inclined face (163b) of the outer foot (163) simultaneously. The third front wing (154) of the third chassis (150) is formed in the following structure: A third front wing central part (154a) that protrudes from the front edge of the third plate (151) toward the second magnetic coil (170) side and can be in close contact with the center of the front face (171f) of the base part (171) of the second magnetic coil (170). Third front wing bending parts (154b) that symmetrically extend left and right from the third front wing central part (154a) and can be in close contact with the outer face of the front face (171f) of the base part (171) of the second magnetic coil (170) and the outer foot (173) simultaneously. The third rear wing (155) of the third chassis (150) is formed in the following structure: A third rear wing central part (155a) that protrudes from the rear edge of the third plate (151) toward the second magnetic coil (170) side and can be in close contact with the center of the rear face (171r) of the base part (171) of the second magnetic coil (170). Third rear wing bending parts (155b) that symmetrically extend left and right from the rear wing central part (155a) and can be in close contact with the outer face of the rear face (171r) of the base part (171) of the second magnetic coil (170) and the outer foot (173) simultaneously. The outer face of the outer foot (173) of the second magnetic coil (170) is formed in the following structure: A central horizontal face (173a); and A pair of inclined faces (173b) that symmetrically and inwardly incline from the horizontal face (173a). The third front wing bending part (154b) is bent inwardly and recessedly so as to be in close contact with the front face (171f) of the base part (171) of the second magnetic coil (170) and the inclined face (173b) of the outer foot (173) simultaneously. The third rear wing bending part (155b) is bent inwardly and recessedly so as to be in close contact with the rear face (171r) of the base part (171) of the second magnetic coil (170) and the inclined face (173b) of the outer foot (173) simultaneously.

7. The transformer for an in-vehicle charger of an electric vehicle according to claim 4, wherein A lower stepped edge (142c) is formed on the outer peripheral surface of the second lower support tube (142). An upper stepped edge (143c) is formed on the outer peripheral surface of the second upper support tube (143). The lower stepped edge (142c) is supported with a step by the upper end of the first support tube (132), so that the first support tube (132) and the second lower support tube (142) are axially arranged in an overlapping manner. In a state where the first support tube (132) and the second lower support tube (142) are axially arranged in an overlapping manner, the outer peripheral surfaces of the first support tube (132) and the second lower support tube (142) form the same plane. The lower end of the third support tube (152) is supported with a step by the upper stepped edge (143c), so that the second upper support tube (143) and the third support tube (152) are axially arranged in an overlapping manner. In a state where the second upper support tube (143) and the third support tube (152) are axially arranged in an overlapping manner, the outer peripheral surfaces of the third support tube (152) and the second upper support tube (143) form the same plane.

8. The transformer for an on-vehicle charger of an electric vehicle according to claim 4, wherein A plurality of second lower insertion grooves (142b) are recessed at equal intervals on the outer peripheral edge of the second lower support tube (142). A first insertion protrusion (132b) that is inserted and coupled to the second lower insertion groove (142b) is formed on the inner peripheral surface of the first support tube (132) of the first chassis (130). A plurality of second upper insertion grooves (143b) are recessed at equal intervals on the outer peripheral edge of the second upper support tube (143). A third insertion protrusion (152b) that is inserted and coupled to the second upper insertion groove (143b) is formed on the inner peripheral surface of the third support tube (152) of the third chassis (150).

9. The transformer for an on-vehicle charger of an electric vehicle according to claim 4, wherein A protrusion portion (145) that protrudes rearward from the rear surface of the second disk (141) and has a flat rear surface (145r) is formed. The rear surface (135r) of the first rear wing (135) is a flat surface. The rear surface (155r) of the third rear wing (155) is a flat surface. The rear surfaces (145r) of the protrusion portion (145), the rear surface (135r) of the first rear wing (135), and the rear surface (155r) of the third rear wing (155) are all formed in the same vertical plane.

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