Magnetic integrated LLC transformer

Abstract

The invention discloses a magnetic integrated LLC transformer. The transformer comprises a copper bar, a magnetic core, a shell, an insulating sleeve, heat-conducting silica gel, an insulating sheet and a coil, and the coil, the magnetic core and the insulating sheet are arranged in the shell. According to the magnetic integrated LLC transformer provided by the invention, the detachable magnetic cores are arranged outside the transformer coil and the resonant inductance coil, a plurality of magnetic cores are combined to form a magnetic path, and the resonant inductance coil is integrated into the transformer, so that the overall size is reduced; the whole device is rectangular and is suitable for being installed in a small rectangular space. The structure is simplified, and machining is easier. The shell is filled with heat-conducting silica gel, large-area heat dissipation is provided for the peripheries of the coil and the magnetic core, heat in the transformer is conducted to the shell, stable operation of the transformer is guaranteed, and meanwhile the filled heat-conducting silica gel can stabilize the position of the magnetic core and prevent deviation.

Description

Technical Field

[0001] The present invention belongs to the technical field of transformers, and particularly relates to a magnetically integrated LLC transformer with efficient heat dissipation. Background Art

[0002] Most of the existing LLC transformers are composed of a resonant inductor winding and a transformer. At present, the development trend of society is that electronic devices are becoming more and more miniaturized, integrated, thin and light. Since the resonant inductor winding and the transformer of the traditional LLC transformer are two independent components, the volume of the common LLC transformer is relatively large, and it cannot meet the increasingly compact design space. The more compact the structure of the transformer is, the more problems of heat dissipation and structural stability of the transformer need to be considered. Therefore, it is necessary to design an LLC transformer that can meet the current design requirements. Summary of the Invention

[0003] In order to solve the above problems, the purpose of the present invention is to provide a magnetically integrated LLC transformer.

[0004] In order to achieve the above purpose, the magnetically integrated LLC transformer provided by the present invention includes a copper bar, a magnetic core, a housing, an insulating sleeve, thermal conductive silicone, an insulating sheet and a coil; the coil, the magnetic core and the insulating sheet are installed inside the housing, wherein the coil includes a transformer coil and a resonant inductor coil; the transformer coil is composed of three primary coils and two secondary coils arranged alternately; the resonant inductor coil is connected in series with one primary coil on one side, and the transformer coil and the resonant inductor coil are coaxially installed and magnetically integrated together; an insulating sheet for isolation is provided between adjacent primary coils and secondary coils, between the resonant inductor coil and the primary coil, and on the outer sides of the transformer coil and the resonant inductor coil; a tap of the primary coil is connected to a tap of the resonant inductor coil, so that the transformer coil and the resonant inductor coil form an integral body, and two taps at the outer end of the resonant inductor coil are led out from the upper end of the housing, and the taps are wrapped by an insulating sleeve outside; the magnetic core includes two transformer magnetic cores and a resonant inductor magnetic core; both the transformer magnetic core and the resonant inductor magnetic core are in a concave shape; the two transformer magnetic cores are arranged around the outside of the transformer coil with their openings facing each other; the resonant inductor magnetic core is arranged around the outside of the resonant inductor coil; the thermal conductive silicone is filled in the gap between the magnetic core and the housing; the copper bar is composed of two busbar copper bars and four copper bar coils; a copper bar coil is installed at each of the two sides at the top of each secondary coil, and the copper bar coils are located outside the upper end of the housing; one end of each busbar copper bar is inserted and fixed in the two copper bar coils on the same side for leading out the large current output by the secondary side of the transformer.

[0005] Both the transformer magnetic core and the resonant inductor magnetic core are made of manganese-zinc ferrite.

[0006] The outer shell is a cuboid structure made of aluminum, and fixing screw holes are provided on both sides of the bottom. The magnetically integrated LLC transformer is fixed on the water-cooled heat dissipation plate by screws.

[0007] The secondary side coil is a copper bar winding, and the primary side coil is a coil winding.

[0008] The height and length of the busbar are adjustable to meet the requirements of the rear-end connection.

[0009] A round hole is formed at the center of the magnetic core for heat dissipation.

[0010] The present invention has the following beneficial effects:

[0011] For the magnetically integrated LLC transformer provided by the present invention, a detachable magnetic core is arranged outside the transformer coil and the resonant inductor coil. A magnetic path is formed by combining multiple magnetic cores, and the resonant inductor coil is integrated into the transformer, reducing the overall volume; the whole is rectangular and suitable for installation in a small rectangular space; the structure is simplified and the processing is easier. The inside of the outer shell is filled with thermal conductive silica gel, which provides a large area for heat dissipation around the coil and the magnetic core, conducts the heat inside the transformer to the outer shell, ensures the stable operation of the transformer, and at the same time, the filled thermal conductive silica gel can fix the position of the magnetic core to prevent deviation. Description of the Drawings

[0012] Figure 1 It is a schematic diagram of the overall structure of the magnetically integrated transformer provided by the present invention;

[0013] Figure 2 It is a schematic diagram of the internal structure of the magnetically integrated transformer provided by the present invention;

[0014] Figure 3 It is a schematic diagram of the coil structure in the magnetically integrated transformer provided by the present invention;

[0015] Figure 4 It is a schematic diagram of the magnetic core structure in the magnetically integrated transformer provided by the present invention. Detailed Embodiments

[0016] The present invention will be described in detail below with reference to the drawings.

[0017] As Figures 1 - 4As shown in the figure, the magnetically integrated LLC transformer provided by the present invention includes a copper bar 1, a magnetic core 2, a housing 3, an insulating sleeve 4, a thermal conductive silicone 5, an insulating sheet 8, and coils; the coils, the magnetic core 2, and the insulating sheet 8 are installed inside the housing 3, wherein the coils include a transformer coil 6 and a resonant inductor coil 7; the transformer coil 6 is composed of three primary coils 602 and two secondary coils 601 arranged alternately; the resonant inductor coil 7 is connected in series with one of the primary coils 602 located on one side, and the transformer coil 6 and the resonant inductor coil 7 are coaxially installed and magnetically integrated together; an insulating sheet 8 for isolation is provided between adjacent primary coils 602 and secondary coils 601, between the resonant inductor coil 7 and the primary coil 602, and on the outer sides of the transformer coil 6 and the resonant inductor coil 7; a tap of the primary coil 602 is connected to a tap of the resonant inductor coil 7, so that the transformer coil 6 and the resonant inductor coil 7 form a whole, and two taps at the outer end of the resonant inductor coil 7 are led out from the upper end of the housing 3, and the outside of the taps is wrapped by the insulating sleeve 4; the magnetic core 2 includes two transformer magnetic cores 201 and a resonant inductor magnetic core 202; both the transformer magnetic core 201 and the resonant inductor magnetic core 202 are of concave-shaped structures; the two transformer magnetic cores 201 are arranged around the outside of the transformer coil 6 with their openings facing each other; the resonant inductor magnetic core 202 is arranged around the outside of the resonant inductor coil 7; the thermal conductive silicone 5 is filled in the gap between the magnetic core 2 and the housing 3, which is convenient for conducting the heat generated by the coils and the magnetic core 2 to the outside of the housing 3 to improve the heat dissipation efficiency, and at the same time fixes the coils, the magnetic core 2, and the insulating sheet 8; the copper bar 1 is composed of two busbar copper bars 101 and four copper bar coils 102; a copper bar coil 102 is installed on each of the two side parts at the top of each secondary coil 601, and the copper bar coils 102 are located outside the upper end of the housing 3; one end of each busbar copper bar 101 is inserted and fixed in two copper bar coils 102 located on the same side for leading out the large current output from the secondary side of the transformer.

[0018] Both the transformer magnetic core 201 and the resonant inductor magnetic core 202 are made of manganese-zinc ferrite.

[0019] The housing 3 is a cuboid structure made of aluminum, and fixing screw holes are provided on both sides of the bottom, and the magnetically integrated LLC transformer can be fixed on the water-cooled heat dissipation plate by screws, so as to take away the heat generated by the transformer, and this design can make the contact area between the transformer and the bottom water-cooled heat dissipation plate larger and the installation more stable.

[0020] The secondary coil 601 is a copper bar winding, and the primary coil 602 is a coil winding.

[0021] The height and length of the busbar copper bar 101 are adjustable to meet the requirements of the subsequent connection.

[0022] A round hole is formed at the center of the magnetic core 2 for heat dissipation.

[0023] The assembly method of the magnetic integrated LLC transformer provided by the present invention is as follows:

[0024] First, wind the coils, isolate each coil with the insulating sheet 8, then install multiple magnetic cores 2 outside the coils, then install the assembled structural components inside the housing 3, install the copper busbar 1, and finally fill with thermal conductive silicone 5.

[0025] For the magnetic integrated LLC transformer provided by the present invention, a magnetic core 2 is arranged outside the coil to form a magnetic path, which functions as a resonant inductor, enabling the volume of the magnetic integrated LLC transformer to be reduced and processing to be more convenient. The magnetic integrated LLC transformer is overall in a rectangular structure and is suitable for installation in a narrow space. In terms of structural design, large heat dissipation areas are provided at the top and around the magnetic integrated LLC transformer, and its heat can be directly dissipated into the air, or a radiator can be installed at the bottom to take away the heat by the radiator. Mounting screw holes are provided on both sides of the housing 3, enabling the magnetic integrated LLC transformer to be stably installed.

Claims

1. A magnetic integrated LLC transformer, characterized in that: The magnetic integrated LLC transformer includes a copper bar (1), a magnetic core (2), a housing (3), an insulating sleeve (4), thermal conductive silicone (5), an insulating sheet (8), and coils. The coils, the magnetic core (2), and the insulating sheet (8) are installed inside the housing (3). The coils include a transformer coil (6) and a resonant inductor coil (7). The transformer coil (6) is composed of three primary coils (602) and two secondary coils (601) arranged alternately. The resonant inductor coil (7) is connected in series with one primary coil (602) located on one side, and the transformer coil (6) and the resonant inductor coil (7) are coaxially installed and magnetically integrated. An insulating sheet (8) for isolation is provided between adjacent primary coils (602) and secondary coils (601), between the resonant inductor coil (7) and the primary coil (602), and on the outer sides of the transformer coil (6) and the resonant inductor coil (7). A tap of the primary coil (602) is connected to a tap of the resonant inductor coil (7) to form an integral body of the transformer coil (6) and the resonant inductor coil (7). Two taps are led out from the outer end of the resonant inductor coil (7) to the outside from the upper end of the housing (3), and the outside of the taps is wrapped by the insulating sleeve (4). The magnetic core (2) includes two transformer magnetic cores (201) and one resonant inductor magnetic core (202). Both the transformer magnetic core (201) and the resonant inductor magnetic core (202) are of concave-shaped structures. The two transformer magnetic cores (201) are arranged around the outside of the transformer coil (6) with their openings facing each other. The resonant inductor magnetic core (202) is arranged around the outside of the resonant inductor coil (7). The thermal conductive silicone (5) is filled in the gap between the magnetic core (2) and the housing (3). The copper bar (1) is composed of two busbar copper bars (101) and four copper bar coils (102). One copper bar coil (102) is installed at each of the two top sides of each secondary coil (601), and the copper bar coils (102) are located outside the upper end of the housing (3). One end of each busbar copper bar (101) is inserted and fixed into two copper bar coils (102) on the same side for leading out the large current output from the secondary side of the transformer.

2. The magnetically integrated LLC transformer according to claim 1, wherein: Both the transformer magnetic core (201) and the resonant inductor magnetic core (202) are made of manganese-zinc ferrite.

3. The magnetically integrated LLC transformer according to claim 1, wherein: The housing (3) is a cuboid structure made of aluminum, and fixing screw holes are provided on both sides of the bottom. The magnetic integrated LLC transformer is fixed on the water-cooled heat dissipation plate by screws.

4. The magnetically integrated LLC transformer according to claim 1, wherein: The secondary coil (601) is a copper bar winding, and the primary coil (602) is a coil winding.

5. The magnetically integrated LLC transformer according to claim 1, wherein: The height and length of the busbar copper bar (101) are adjustable to meet the requirements of the rear-end connection.

6. The magnetically integrated LLC transformer according to claim 1, wherein: A round hole is formed at the center of the magnetic core (2) for heat dissipation.

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