Leakage inductance integrated magnetic device and assembling method thereof

Abstract

The invention provides a leakage inductance integrated magnetic device and an assembling method thereof.The leakage inductance integrated magnetic device is provided with a plurality of transformers and a base, the transformers are connected in parallel, the base comprises a plurality of positioning clamping grooves, the transformers are assembled in the positioning clamping grooves respectively, each transformer comprises a plurality of integrated structures, and the integrated structures are connected in series; each integrated structure comprises a PQ type magnetic core structure, a framework, a primary winding and a secondary winding, each PQ type magnetic core structure comprises a first U-shaped magnetic core half body and a second U-shaped magnetic core half body, the first U-shaped magnetic core half body and the second U-shaped magnetic core half body are symmetrically closed, the framework is embedded into a central column body of the first U-shaped magnetic core half body, the primary winding is embedded into the framework in a coil mode, and the secondary winding is embedded into the central column body of the second U-shaped magnetic core half body. And the secondary winding is embedded into the central cylinder of the second U-shaped magnetic core half body in the form of a wire cake, so that the high-power output requirement of the leakage inductance integrated magnetic device is met, the electrical performance and the structural layout of the leakage inductance integrated magnetic device are optimized, and the space and the preparation cost of the whole machine are saved.

Description

Technical Field

[0001] The present invention relates to the field of transformers, and in particular to a leakage inductance integrated magnetic device and an assembly method thereof. Background Art

[0002] In modern society, power electronics are accelerating toward miniaturization, integration, and high-end development. This trend not only places stringent demands on component performance but also presents unprecedented opportunities and challenges for the component manufacturing industry. For example, in-vehicle OBC devices, their power boards widely utilize CLLC circuit topologies. Key components such as transformers and inductors face significant challenges in terms of power, voltage, and current carrying.

[0003] The traditional production method usually uses an independent transformer and an independent resonant inductor, combined with a conventional bobbin structure and an ordinary magnetic core structure. In this mode, due to the large current required to be carried, thicker wires and large magnetic cores must be used, which directly leads to the bulky size of the product. In the limited space of on-board equipment, it not only takes up too much space, but also fails to meet the urgent demand for miniaturization of the entire machine. Moreover, the traditional assembly process is cumbersome. From wire winding, magnetic core assembly, glue dispensing and baking, to oil dipping, potting glue and other processes, all require single-person single-machine operation, with an extremely low degree of automation, making large-scale production impossible. This not only leads to low production efficiency, but also makes labor costs and material costs remain high, and the product cost competitiveness is weak. Summary of the Invention

[0004] The main purpose of the embodiments of the present invention is to propose a leakage inductance integrated magnetic device and an assembly method thereof, which can meet the high-power output requirements of the leakage inductance integrated magnetic device, optimize the electrical performance and structural layout of the leakage inductance integrated magnetic device, and save the overall space and preparation cost.

[0005] To achieve the above objectives, a first aspect of an embodiment of the present invention provides a leakage inductance integrated magnetic device, comprising: Multiple transformers, each connected in parallel, each transformer comprising a plurality of integrated structures, each of which is connected in series, each integrated structure comprising a PQ-type magnetic core structure, a bobbin, a primary winding, and a secondary winding, the PQ-type magnetic core structure comprising a first U-shaped magnetic core half and a second U-shaped magnetic core half, the first U-shaped magnetic core half and the second U-shaped magnetic core half being symmetrically closed, the bobbin being embedded in the central column of the first U-shaped magnetic core half, the primary winding being embedded in the bobbin in the form of a coil, and the secondary winding being embedded in the central column of the second U-shaped magnetic core half in the form of a coil; The base includes a plurality of positioning slots and a plurality of spacers, each spacer is respectively arranged above the interval between each positioning slot, each transformer is respectively assembled in each positioning slot, and the spacer is used to electromagnetically isolate the transformer.

[0006] Furthermore, in some embodiments, a first thermal conductive hole is provided on the outer side surface of the first U-shaped magnetic core half, and a second thermal conductive hole is provided on the outer side surface of the second U-shaped magnetic core half. The first thermal conductive hole is located at the upper edge or the lower edge of the outer side surface of the first U-shaped magnetic core half, and the second thermal conductive hole is located at the upper edge or the lower edge of the outer side surface of the second U-shaped magnetic core half. The position of the first thermal conductive hole corresponds to the position of the second thermal conductive hole.

[0007] Furthermore, in some embodiments, the first thermal conductive via or the second thermal conductive via is a V-shaped opening.

[0008] Furthermore, in some embodiments, a first terminal block is provided at the bottom of the base, and the first terminal block is located on one side of the base. The primary windings in each transformer are electrically connected to the first terminal block, and the first terminal block is used as an outlet port for the primary winding and the external circuit.

[0009] Furthermore, in some embodiments, a second terminal block is provided at the bottom of the base, and the second terminal block is located on one side of the base. The secondary windings in each transformer are electrically connected to the second terminal block, and the second terminal block is used as an outlet port for the secondary winding and the external circuit.

[0010] Furthermore, in some embodiments, a first parallel contact structure is provided at the bottom of the base, and the primary windings in each transformer are electrically connected to the first parallel contact structure respectively, and the first parallel contact structure is used to connect the primary windings in each transformer in parallel.

[0011] Furthermore, in some embodiments, a second parallel contact structure is provided at the bottom of the base, and the secondary windings in each transformer are electrically connected to the second parallel contact structure respectively, and the second parallel contact structure is used to connect the secondary windings in each transformer in parallel.

[0012] To achieve the above-mentioned object, a second aspect of an embodiment of the present invention provides a method for assembling a leakage inductance integrated magnetic device, comprising: Obtain a base, a plurality of PQ-type magnetic core structures, a plurality of bobbins, a plurality of primary windings, and a plurality of secondary windings; Winding each primary winding on each frame in the form of a coil to obtain a plurality of first assemblies; Embedding each first assembly into the central column of the first U-shaped magnetic core half of each PQ-shaped magnetic core structure to obtain a plurality of second assemblies; Embedding each secondary winding in the form of a coil into the central column of the second U-shaped magnetic core half of each PQ-type magnetic core structure to obtain a plurality of third assemblies; The second assemblies and the third assemblies are symmetrically closed by glue fixation to obtain multiple integrated structures; gluing the plurality of integrated structures in pairs to obtain a plurality of fourth assemblies; Conducting circuit connections inside each fourth assembly to obtain a plurality of transformers; Each transformer is assembled into the base by glue fixation, and circuit connections are made to each transformer on the base to obtain a leakage inductance integrated magnetic device.

[0013] Furthermore, in some embodiments, circuit connections are made inside each fourth assembly, including: connecting the primary winding of one integrated structure in each fourth assembly in series with the primary winding of another integrated structure; The secondary winding of one integrated structure in each fourth assembly is connected in parallel with the secondary winding of another integrated structure.

[0014] Furthermore, in some embodiments, circuit connection is performed on each transformer on the base, including: Connecting one terminal of the primary winding of each transformer to the first parallel contact structure of the base in a corresponding circuit, so that a first parallel circuit is formed between the transformers based on their corresponding primary windings; Connecting one terminal of the secondary winding of each transformer to the second parallel contact structure of the base in a corresponding circuit, so that a second parallel circuit is formed between the transformers based on their corresponding secondary windings; Connecting the other connection terminal of the primary winding of each transformer to the first terminal block of the base in a corresponding circuit, so that each transformer provides a first connection port to the external circuit; The other connection end of the secondary winding of each transformer is connected to the second terminal block of the base in a corresponding circuit, so that each transformer provides a second connection port for the external circuit.

[0015] The embodiments of the present invention have the following beneficial effects: by providing multiple transformers and bases, each transformer is connected in parallel, the base includes multiple positioning slots and multiple spacers, each spacer is respectively provided above the interval between each positioning slot, and each transformer is respectively assembled in each positioning slot, wherein the transformer includes multiple integrated structures, the multiple integrated structures are connected in series, and each integrated structure includes a PQ-type magnetic core structure, a skeleton, a primary winding and a secondary winding, the PQ-type magnetic core structure includes a first U-shaped magnetic core half and a second U-shaped magnetic core half, and the first U-shaped magnetic core half and the second U-shaped magnetic core half are symmetrically closed. The skeleton is embedded in the central column of the first U-shaped magnetic core half, the primary winding is embedded in the skeleton in the form of a wire package, and the secondary winding is embedded in the central column of the second U-shaped magnetic core half in the form of a wire cake. The gap between the primary winding and the secondary winding can be used to control the leakage inductance by controlling the wall thickness of the skeleton, so that the whole constitutes a resonant inductor, forming an integrated LLC transformer with a main and resonant inductor. The transformer is connected in an internal series and external parallel manner, which not only meets the high-power output requirements of the leakage inductance integrated magnetic device, but also optimizes the electrical performance and structural layout of the leakage inductance integrated magnetic device, saving the space and preparation cost of the entire machine. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is an optional overall structural diagram of the leakage inductance integrated magnetic device provided in an embodiment of the present invention; Figure 2 is an optional exploded diagram of the leakage inductance integrated magnetic device provided in an embodiment of the present invention; Figure 3 is another optional exploded diagram of the leakage inductance integrated magnetic device provided in an embodiment of the present invention; Figure 4 This is an optional bottom view of the leakage inductance integrated magnetic device provided in an embodiment of the present invention; Figure 5 This is an optional flow chart of an assembly method of a leakage inductance integrated magnetic device provided in an embodiment of the present invention; Figure 6 This is an optional flow chart for performing circuit connections inside each fourth assembly provided by an embodiment of the present invention; Figure 7 This is an optional flow chart for performing circuit connections on each transformer provided by an embodiment of the present invention.

[0017] Description of the drawings: transformer 1000, integrated structure 1100, PQ-type magnetic core structure 1110, first U-shaped magnetic core half 1111, second U-shaped magnetic core half 1112, first thermal conductive hole 1113, second thermal conductive hole 1114, skeleton 1120, primary winding 1130, secondary winding 1140, base 2000, positioning slot 2100, spacer 2200, first terminal block 2300, second terminal block 2400, first parallel contact structure 2500, second parallel contact structure 2600. DETAILED DESCRIPTION

[0018] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0019] In the description of the present invention, it should be understood that descriptions involving orientations, such as up, down, front, back, left, right, etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, they cannot be understood as limitations on the present invention.

[0020] It should also be noted that, in the description of the present invention, "several" means more than one, "plurality" means more than two, "greater than," "less than," and "exceed" are understood to exclude the number itself, while "above," "below," and "within" are understood to include the number itself. The use of "first" and "second" in the description is solely for the purpose of distinguishing technical features and should not be construed as indicating or implying relative importance, implicitly specifying the number of the indicated technical features, or implicitly specifying the order of the indicated technical features.

[0021] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which the present invention pertains. The terms used herein are for the purpose of describing embodiments of the present invention only and are not intended to limit the present invention.

[0022] In the description of the present invention, reference to terms such as "one embodiment," "some embodiments," "illustrative embodiments," "examples," "specific examples," or "some examples" means that the specific features, structures, materials, or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the exemplary expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0023] The traditional production method usually uses an independent transformer and an independent resonant inductor, combined with a conventional bobbin structure and an ordinary magnetic core structure. In this mode, due to the large current required to be carried, thicker wires and large magnetic cores must be used, which directly leads to the bulky size of the product. In the limited space of on-board equipment, it not only takes up too much space, but also fails to meet the urgent demand for miniaturization of the entire machine. Moreover, the traditional assembly process is cumbersome. From wire winding, magnetic core assembly, glue dispensing and baking, to oil dipping, potting glue and other processes, all require single-person single-machine operation, with an extremely low degree of automation, making large-scale production impossible. This not only leads to low production efficiency, but also makes labor costs and material costs remain high, and the product cost competitiveness is weak.

[0024] Furthermore, traditional structures also have drawbacks in heat dissipation. Within a sealed space, heat generated by the magnetic core and coils is difficult to dissipate effectively, severely impacting the stability and reliability of electrical performance. As market demand for power electronics continues to grow, the shortcomings of this conventional structure in terms of space utilization, assembly ease, and cost control have become increasingly apparent, necessitating an innovative solution to meet the evolving demands of the industry.

[0025] Based on this, an embodiment of the present invention provides a leakage inductance integrated magnetic device and an assembly method thereof, which can meet the high-power output requirements of the leakage inductance integrated magnetic device, optimize the electrical performance and structural layout of the leakage inductance integrated magnetic device, and save the overall machine space and preparation cost.

[0026] An embodiment of the present invention provides a leakage inductance integrated magnetic device and an assembly method thereof, which are specifically described through the following embodiments.

[0027] First, refer to Figure 1 、 Figure 2 、 Figure 3 and Figure 4 As shown, Figure 1 is an optional overall structural diagram of the leakage inductance integrated magnetic device provided in an embodiment of the present invention. Figure 2 is an optional exploded diagram of the leakage inductance integrated magnetic device provided in an embodiment of the present invention. Figure 3 is another optional exploded diagram of the leakage inductance integrated magnetic device provided in an embodiment of the present invention, Figure 4This is an optional bottom view of a leakage inductance integrated magnetic device provided by an embodiment of the present invention, wherein the leakage inductance integrated magnetic device includes a plurality of transformers 1000 and a base 2000, wherein each transformer 1000 is connected in parallel, and the transformer 1000 includes a plurality of integrated structures 1100, wherein the plurality of integrated structures 1100 are connected in series, and each integrated structure 1100 includes a PQ-type magnetic core structure 1110, a skeleton 1120, a primary winding 1130, and a secondary winding 1140, wherein the PQ-type magnetic core structure 1110 includes a first U-shaped magnetic core half 1111 and a second U-shaped magnetic core half 1112, and the first U-shaped magnetic core half 1111 is connected to the first U-shaped magnetic core half 1112. The skeleton 1120 is symmetrically closed with the second U-shaped magnetic core half 1112, and is embedded in the central column of the first U-shaped magnetic core half 1111. The primary winding 1130 is embedded in the skeleton 1120 in the form of a wire package, and the secondary winding 1140 is embedded in the central column of the second U-shaped magnetic core half 1112 in the form of a wire cake, thereby realizing that the transformer 1000 is formed by magnetic conversion between the primary winding 1130 and the secondary winding 1140. The secondary winding 1140 is combined in the form of a wire cake, and the primary winding 1130 is wound by the skeleton 1120. The gap between the primary winding 1130 and the secondary winding 1140 is utilized to control the leakage inductance by controlling the wall thickness of the skeleton 1120, so that the whole constitutes a resonant inductance, forming an integrated LLC transformer 1000 with a main and a resonant body.

[0028] It should be noted that transformer 1000 operates based on the law of electromagnetic induction. When AC current is applied to primary winding 1130, an alternating magnetic field is generated. PQ-type magnetic core structure 1110 guides this magnetic field through secondary winding 1140, generating an induced electromotive force. Multiple integrated structures 1100 are connected in series, with secondary winding 1140 formed as a coiled coil. Primary winding 1130 is wound around bobbin 1120, optimizing magnetic field coupling.

[0029] Among them, reference Figure 2 and Figure 3 As shown, the base 2000 includes a plurality of positioning slots 2100 and a plurality of spacers 2200. Each spacer 2200 is respectively arranged above the interval between each positioning slot 2100. Each transformer 1000 is respectively assembled in each positioning slot 2100. The spacer 2200 is used to electromagnetically isolate the transformer 1000.

[0030] It is worth noting that the base 2000 is isolated by adopting the positioning slot 2100 and the spacer 2200, which not only facilitates the automatic dispensing operation of the dispensing equipment on the base 2000, but also ensures the accuracy and stability of the glue fixation, thereby making the edge set on the base 2000 effectively prevent the glue from flowing, so that the transformer 1000 and the base 2000 are tightly bonded together.

[0031] In one embodiment, the total power of the leakage inductance integrated magnetic device is 22 kW, and the leakage inductance integrated magnetic device includes three 6.6 kW transformers 1000 connected in parallel.

[0032] It should also be noted that the transformer 1000 is connected in series internally and in parallel externally, so that the original independent components, a transformer 1000 and a resonant inductor, can be integrated into a separate small transformer 1000 from the CLLC circuit topology structure, thereby realizing a main-resonant integrated transformer 1000, which not only meets the high-power output requirements of the leakage inductance integrated magnetic device, but also optimizes the electrical performance and structural layout of the leakage inductance integrated magnetic device, saving the space and preparation cost of the entire machine.

[0033] Further, refer to Figure 2 and Figure 3 As shown, a first heat conducting hole 1113 is provided on the outer side of the first U-shaped magnetic core half 1111, and a second heat conducting hole 1114 is provided on the outer side of the second U-shaped magnetic core half 1112. The first heat conducting hole 1113 is located at the upper edge or the lower edge of the outer side of the first U-shaped magnetic core half 1111, and the second heat conducting hole 1114 is located at the upper edge or the lower edge of the outer side of the second U-shaped magnetic core half 1112. The position of the first heat conducting hole 1113 corresponds to the position of the second heat conducting hole 1114.

[0034] It should be noted that the PQ-type magnetic core structure 1110 can not only improve the heat dissipation efficiency inside the PQ-type magnetic core structure 1110 through the double-sided heat conduction hole design, but also control the magnetic resistance inside the PQ-type magnetic core structure 1110, adjust the inductance and leakage inductance, and improve the electromagnetic conversion efficiency.

[0035] In some possible embodiments, the first heat conducting hole 1113 or the second heat conducting hole 1114 is a V-shaped opening.

[0036] It should be noted that the integrated structure 1100 in the leakage inductor integrated magnetic device utilizes a PQ-type magnetic core structure 1110. This PQ-type magnetic core structure 1110 is characterized by sufficient flow between the inner surface of the core winding and its central column. This design allows the epoxy glue to flow fully into the leakage inductor integrated magnetic device. During operation, heat generated by the core and windings is efficiently conducted and dissipated through the epoxy glue, significantly improving heat dissipation performance and ensuring the stability of the leakage inductor integrated magnetic device under high load operation.

[0037] Further, refer to Figure 4As shown, a first terminal block 2300 is provided at the bottom of the base 2000. The first terminal block 2300 is located on one side of the base 2000. The primary winding 1130 in each transformer 1000 is electrically connected to the first terminal block 2300 respectively. The first terminal block 2300 is used as an outlet port for the primary winding 1130 and the external circuit.

[0038] Further, refer to Figure 4 As shown, a second terminal block 2400 is also provided at the bottom of the base 2000. The second terminal block 2400 is located on one side of the base 2000. The secondary windings 1140 in each transformer 1000 are electrically connected to the second terminal block 2400 respectively. The second terminal block 2400 is used as an outlet port for the secondary winding 1140 and the external circuit.

[0039] It should be noted that the reference Figure 4 As shown, the base 2000 greatly simplifies the circuit connection process of the leakage inductance integrated magnetic device by providing the first terminal block 2300 and the second terminal block 2400, thereby improving assembly efficiency and operation convenience.

[0040] Further, refer to Figure 4 As shown, a first parallel contact structure 2500 is further provided at the bottom of the base 2000 , and the primary windings 1130 in each transformer 1000 are electrically connected to the first parallel contact structure 2500 , respectively. The first parallel contact structure 2500 is used to connect the primary windings 1130 in each transformer 1000 in parallel.

[0041] Further, refer to Figure 4 As shown, a second parallel contact structure 2600 is further provided at the bottom of the base 2000 , and the secondary windings 1140 in each transformer 1000 are electrically connected to the second parallel contact structure 2600 , respectively. The second parallel contact structure 2600 is used to connect the secondary windings 1140 in each transformer 1000 in parallel.

[0042] It should be noted that the modular parallel contact connection method simplifies the wiring complexity of multiple transformers 1000 working together, which is convenient for equipment expansion and maintenance. At the same time, the secondary windings 1140 in each transformer 1000 are connected in parallel to form a low-impedance output loop of the leakage inductance integrated magnetic device, which is beneficial to improve the dynamic response speed and ensure the stability of the output voltage. It is particularly suitable for high-power, high-reliability power electronics application scenarios.

[0043] Secondly, refer to Figure 5 As shown, Figure 5 This is an optional flow chart of an assembly method of a leakage inductance integrated magnetic device provided in an embodiment of the present invention. The method may include but is not limited to steps S101 to S108.

[0044] Step S101: obtaining a base, a plurality of PQ-type magnetic core structures, a plurality of bobbins, a plurality of primary windings, and a plurality of secondary windings.

[0045] Step S102: Winding each primary winding on each frame in the form of a coil to obtain a plurality of first assemblies.

[0046] Step S103 : embedding each first assembly into the central column of each first U-shaped magnetic core half of the PQ-shaped magnetic core structure to obtain a plurality of second assemblies.

[0047] Step S104 : embedding each secondary winding in the form of a coil into the central column of the second U-shaped magnetic core half of each PQ-type magnetic core structure to obtain a plurality of third assemblies.

[0048] Step S105: symmetrically closing each second assembly body and the third assembly body by glue-fixing to obtain a plurality of integrated structures.

[0049] Step S106: gluing the plurality of integrated structures in pairs to obtain a plurality of fourth assemblies.

[0050] Step S107: performing circuit connection on the interior of each fourth assembly to obtain a plurality of transformers.

[0051] Step S108: assembling each transformer into the base by glue-fixing, and performing circuit connection on each transformer on the base to obtain a leakage inductance integrated magnetic device.

[0052] Specifically, each transformer is attached to the base using glue to prevent displacement and maintain a stable magnetic field within the transformer. In one implementation, the three transformers are assembled to the base by welding them together and insulating them. The assembled transformer assembly base is then glued to enhance the overall structural stability of the leakage inductance integrated magnetic device, making it resilient to vibration and shock.

[0053] It's worth noting that the CLLC circuits in existing on-board OBC devices typically consist of transformers and inductors. Due to their high power, voltage, and current requirements, these circuits require thicker wire and larger magnetic cores. Conventional methods typically involve fabricating these components as separate magnetic components: a separate transformer and resonant inductor. However, the existing transformer and inductor manufacturing processes lack the structural characteristics of the existing magnetic cores required for miniaturization and compact size. At the same time, the conventional transformer manufacturing process often requires a single person operating a single machine, resulting in a cumbersome process that cannot be automated. Consequently, large-scale production is impossible, and the power electronics industry's demand for inductor production capacity cannot be met. To meet market demand, a process for automating the production of independent magnetic components is needed, optimizing their size, improving production efficiency, and reducing labor and material costs.

[0054] Therefore, through steps S101 to S108 of the present invention, the overall production process of the leakage inductor integrated magnetic device is significantly optimized, reducing cumbersome process steps, simplifying operation, and possessing high potential for automated production. Compared with the traditional single-person, single-machine production model, automated production not only significantly improves production efficiency, but also reduces labor and material costs, enhancing the competitiveness of the leakage inductor integrated magnetic device.

[0055] Reference Figure 6 As shown, Figure 6 This is an optional flow chart of performing circuit connection inside each fourth assembly provided by an embodiment of the present invention. The method may include but is not limited to steps S201 to S202.

[0056] Step S201 : connecting the primary winding of one integrated structure and the primary winding of another integrated structure in series in each fourth assembly.

[0057] Step S202: connecting the secondary winding of one integrated structure in each fourth assembly in parallel with the secondary winding of another integrated structure.

[0058] It should be noted that the leakage inductance integrated magnetic device of the present invention can determine the electrical parameters by different wire diameters, number of turns and winding methods of each winding. Among them, by connecting the primary winding of an integrated structure in the fourth assembly in series with the primary winding of another integrated structure in the above step S201, the inductance inside the transformer can be increased. By connecting the secondary winding of an integrated structure in the fourth assembly in parallel with the secondary winding of another integrated structure in the above step S201, the DC resistance inside the transformer can be reduced, thereby fully meeting the electrical performance indicators. In addition, the electrical parameters of the pins of the primary winding and the secondary winding are strictly set to ensure that the insulation resistance, dielectric strength and other performance meet the standards, so as to ensure that the leakage inductance integrated magnetic device can operate safely and stably.

[0059] Reference Figure 7 As shown, Figure 7 This is an optional flow chart for performing circuit connection on each transformer provided by an embodiment of the present invention. The method may include but is not limited to steps S301 to S304.

[0060] Step S301: Connecting one terminal of the primary winding of each transformer to the first parallel contact structure of the base in a corresponding circuit, so that a first parallel circuit is formed between each transformer based on the primary winding corresponding to each transformer.

[0061] Step S302: Connecting one terminal of the secondary winding of each transformer to the second parallel contact structure of the base in a corresponding circuit, so that a second parallel circuit is formed between each transformer based on its corresponding secondary winding.

[0062] Step S303: Connecting the other connection terminal of the primary winding of each transformer to the first terminal block of the base in a corresponding circuit, so that each transformer provides a first connection port to the external circuit.

[0063] Step S304: Connect the other connection terminal of the secondary winding of each transformer to the second terminal block of the base in a corresponding circuit, so that each transformer provides a second connection port for the external circuit.

[0064] It should be noted that in step S301 to step S304, the primary windings of each transformer form a parallel circuit through the first parallel contact, evenly distribute the input current, avoid overload of a single transformer, and reduce total harmonic distortion; the secondary windings of each transformer form a low-impedance output circuit through the second parallel contact, which enhances the load capacity and improves the dynamic response. Secondly, the other ends of the primary and secondary windings are respectively led to independent first and second terminal blocks, which not only realizes the centralized management of the input / output interface and simplifies the complexity of external wiring, but also retains the electrical independence of each transformer winding, facilitating fault isolation and modular maintenance. In addition, the discrete design of the terminal block supports flexible multi-channel output configuration or redundant backup solutions, while reducing the risk of electromagnetic interference through physical isolation, so that the system has high reliability, expansion convenience and operational stability in industrial high-power scenarios.

[0065] The embodiments described in the embodiments of the present invention are intended to more clearly illustrate the technical solutions of the embodiments of the present invention and do not constitute a limitation on the technical solutions provided by the embodiments of the present invention. Those skilled in the art will appreciate that with the evolution of technology and the emergence of new application scenarios, the technical solutions provided by the embodiments of the present invention are also applicable to similar technical problems.

[0066] The device embodiments described above are merely illustrative. The devices described as separate components may or may not be physically separate, i.e., they may be located in one location or distributed across multiple network devices. Some or all of the modules may be selected based on actual needs to achieve the objectives of this embodiment.

[0067] The terms "first," "second," "third," "fourth," and so forth (if any) in the description of the present invention and the accompanying drawings are used to distinguish similar objects and are not necessarily used to describe a particular order or precedence. It should be understood that the terms used in this manner are interchangeable where appropriate so that the embodiments of the present invention described herein can be implemented in orders other than those illustrated or described herein. In addition, the terms "including" and "having," and any variations thereof, are intended to cover non-exclusive inclusions. For example, a process, method, system, product, or apparatus that includes a series of steps or devices is not necessarily limited to those steps or devices that are explicitly listed, but may include other steps or devices that are not explicitly listed or that are inherent to such processes, methods, products, or apparatus.

[0068] It should be understood that in the present invention, "at least one (item)" refers to one or more, and "plurality" refers to two or more. "And / or" is used to describe the association relationship of associated objects, indicating that three relationships may exist. For example, "A and / or B" can represent: only A exists, only B exists, and A and B exist at the same time, where A and B can be singular or plural. The character " / " generally indicates that the previous and next associated objects are in an "or" relationship. "At least one of the following items" or similar expressions refers to any combination of these items, including any combination of single items or plural items. For example, at least one of a, b or c can represent: a, b, c, "a and b", "a and c", "b and c", or "a and b and c", where a, b, c can be single or multiple.

[0069] In the several embodiments provided by the present invention, it should be understood that the disclosed system can be implemented in other ways. For example, the system embodiments described above are merely illustrative. For example, the division of the above-mentioned devices is only a logical function division. In actual implementation, there may be other division methods, such as multiple devices or components can be combined or integrated into another system, or some features can be ignored or not executed. In addition, the mutual coupling or direct coupling or communication connection shown or discussed can be an indirect coupling or communication connection through some interface, device or device, which can be electrical, mechanical or other forms.

[0070] The devices described above as separate components may or may not be physically separate, and the components shown as devices may or may not be physical devices, that is, they may be located in one place or distributed across multiple network devices. Some or all of these devices may be selected based on actual needs to achieve the objectives of this embodiment.

[0071] In addition, the functional units in various embodiments of the present invention may be integrated into a single processor, each unit may exist physically separately, or two or more units may be integrated into a single unit. The aforementioned integrated units may be implemented in the form of hardware or software functional units.

[0072] The preferred embodiments of the present invention are described above with reference to the accompanying drawings, but the scope of the invention is not limited thereby. Any modifications, equivalent substitutions, and improvements made by those skilled in the art without departing from the scope and essence of the invention should be within the scope of the invention.

Claims

1. A leakage inductance integrated magnetic device, characterized in that: include: Multiple transformers, each of the transformers is connected in parallel, and the transformers include multiple integrated structures, which are connected in series. The integrated structures each include a PQ-type magnetic core structure, a skeleton, a primary winding, and a secondary winding. The PQ-type magnetic core structure includes a first U-shaped magnetic core half and a second U-shaped magnetic core half, the first U-shaped magnetic core half and the second U-shaped magnetic core half being symmetrically closed. The skeleton is embedded in the central column of the first U-shaped magnetic core half, the primary winding is embedded in the skeleton in the form of a coil, and the secondary winding is embedded in the central column of the second U-shaped magnetic core half in the form of a coil. The base includes a plurality of positioning slots and a plurality of spacers, each of the spacers is respectively arranged above the interval between each of the positioning slots, each of the transformers is respectively assembled in each of the positioning slots, and the spacers are used to electromagnetically isolate the transformers.

2. The leakage inductance integrated magnetic device according to claim 1, characterized in that: A first heat conduction hole is provided on the outer side of the first U-shaped magnetic core half, and a second heat conduction hole is provided on the outer side of the second U-shaped magnetic core half. The first heat conduction hole is located at the upper edge or the lower edge of the outer side of the first U-shaped magnetic core half, and the second heat conduction hole is located at the upper edge or the lower edge of the outer side of the second U-shaped magnetic core half. The position of the first heat conduction hole corresponds to the position of the second heat conduction hole.

3. The leakage inductance integrated magnetic device according to claim 2, characterized in that: The first heat conducting hole or the second heat conducting hole is a V-shaped opening.

4. The leakage inductance integrated magnetic device according to claim 1, characterized in that: A first terminal block is provided at the bottom of the base, and the first terminal block is located on one side of the base. The primary windings in each transformer are electrically connected to the first terminal block respectively, and the first terminal block is used as an outlet port for the primary winding and the external circuit.

5. The leakage inductance integrated magnetic device according to claim 1, characterized in that: A second terminal block is also provided at the bottom of the base, and the second terminal block is located on one side of the base. The secondary windings in each transformer are electrically connected to the second terminal block respectively, and the second terminal block is used as an outlet port for the secondary winding and the external circuit.

6. The leakage inductance integrated magnetic device according to claim 1, characterized in that: A first parallel contact structure is further provided at the bottom of the base, and the primary windings in each of the transformers are electrically connected to the first parallel contact structure respectively. The first parallel contact structure is used to connect the primary windings in each of the transformers in parallel.

7. The leakage inductance integrated magnetic device according to claim 1, characterized in that: A second parallel contact structure is further provided at the bottom of the base, and the secondary windings in each of the transformers are electrically connected to the second parallel contact structure respectively. The second parallel contact structure is used to connect the secondary windings in each of the transformers in parallel.

8. A method for assembling a leakage inductance integrated magnetic device, characterized in that: include: Obtain a base, a plurality of PQ-type magnetic core structures, a plurality of bobbins, a plurality of primary windings, and a plurality of secondary windings; Winding each of the primary windings on each of the frames in the form of coils to obtain a plurality of first assemblies; Embedding each of the first assemblies into the central column of each of the first U-shaped magnetic core halves of the PQ-shaped magnetic core structure to obtain a plurality of second assemblies; Embedding each of the secondary windings in the form of coils into the central column of the second U-shaped magnetic core half of each PQ-type magnetic core structure to obtain a plurality of third assemblies; symmetrically closing each of the second assemblies and the third assemblies by glue-fixing to obtain a plurality of integrated structures; gluing the plurality of integrated structures in pairs to obtain a plurality of fourth assemblies; Performing circuit connections on the interior of each of the fourth assemblies to obtain a plurality of transformers; The transformers are assembled into the base by glue-fixing, and circuit connections are made to the transformers on the base to obtain the leakage inductance integrated magnetic device.

9. The assembly method according to claim 8, characterized in that: The circuit connection of each of the fourth assemblies comprises: connecting the primary winding of one integrated structure in each of the fourth assemblies in series with the primary winding of another integrated structure; The secondary winding of one integrated structure in each of the fourth assemblies is connected in parallel with the secondary winding of another integrated structure.

10. The assembly method according to claim 8, characterized in that: The circuit connection of each transformer on the base includes: Connecting one terminal of the primary winding of each transformer to the first parallel contact structure of the base in a corresponding circuit, so that a first parallel circuit is formed between each transformer based on its corresponding primary winding; Connecting one terminal of the secondary winding of each transformer to the second parallel contact structure of the base in a corresponding circuit, so that a second parallel circuit is formed between each transformer based on its corresponding secondary winding; Connecting the other connection terminal of the primary winding of each transformer to the first terminal block of the base in a corresponding circuit, so that each transformer provides a first connection port to the external circuit; The other connection end of the secondary winding of each transformer is connected to the second terminal block of the base in a corresponding circuit, so that each transformer provides a second connection port for the external circuit.

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