Electric energy conversion apparatus and power supply system

Abstract

The invention provides an electric energy conversion device and a power supply system. The electric energy conversion equipment comprises a first printed circuit board, a second printed circuit board and a transformer, wherein the first printed circuit board and the second printed circuit board are oppositely arranged; the transformer is arranged between the first printed circuit board and the second printed circuit board; gaps are respectively formed between the transformer body and the first printed circuit board and between the transformer body and the second printed circuit board; the transformer comprises at least one group of first-type windings, each group of first-type windings comprises two first-type coils, one first-type coil is led out from the side part, close to the first printed circuit board, of the transformer, and the other first-type coil is led out from the side part, close to the second printed circuit board, of the transformer; the second type winding of the transformer is led out from the side portion, away from the first printed circuit board and the second printed circuit board, of the transformer to the first printed circuit board or the second printed circuit board. According to the electric energy conversion equipment and the power supply system, the heat dissipation performance of the transformer can be improved, and the manufacturing process can be simplified.

Description

Technical Field

[0001] The present application relates to the field of power electronics technology, and in particular to an electric energy conversion device and a power supply system. Background Art

[0002] Common server power supply terminal application single module power supply output voltage is 12V (volts), output power is 500W (watts) ~ 3KW (kilowatts), output current is 40A ~ 250A (amperes), which is a typical low voltage and high current application power supply. Figures 1 to 3 As shown, a common server power transformer 100 consists of a magnetic core 11, a secondary copper sheet winding 12, and a primary wire winding 13. The primary voltage of the transformer 100 is generally a high voltage of more than 300V, and the secondary voltage is 12V. Therefore, the turns ratio of the transformer 100 is large. Therefore, the primary side of the transformer 100 has the characteristics of many turns, high voltage, and low current. Due to the low primary current and large number of turns, the primary winding is mostly wound with wire. The secondary side of the transformer 100 has the characteristics of few turns, low voltage, and high current. Due to the large primary current and small number of turns, the use of wire winding will occupy a large window area, which will increase the size of the transformer. Therefore, the secondary winding is mostly made of copper sheet winding that can withstand high current.

[0003] For low-voltage, high-current transformers like server power supplies, the secondary winding, also known as the output winding, is usually the hottest part and is usually cooled by air. Figures 2 to 4 As shown, the copper sheet 122 on the top of the transformer 100 is generally bent into a flat surface, and heat is conducted away by adding thermal conductive glue 17 or a heat sink on the flat surface. In this way, the structure of the copper sheet 122 is complex, and both heat conduction and assembly require additional processing steps, which increases the complexity of assembly.

[0004] With the widespread application of AI (Artificial Intelligence) servers today, the output power of some single-module power supplies has reached over 10 kW and the output current has reached over 1000 A. Therefore, AI servers have higher requirements for the core transformer of the converter for low-voltage and high-current applications. Summary of the Invention

[0005] In order to solve at least one of the above-mentioned problems existing in the prior art, an embodiment of the present application provides an electric energy conversion device and a power supply system.

[0006] An embodiment of the present application provides an electric energy conversion device, comprising a first and a second printed circuit board arranged opposite to each other, and a transformer arranged between the first and second printed circuit boards; wherein a gap is respectively provided between the main body of the transformer and the first and second printed circuit boards; the transformer comprises: at least one group of first-type windings and second-type windings, wherein each group of first-type windings comprises two first-type coils, one first-type coil extending from a side of the transformer close to the first printed circuit board, and the other first-type coil extending from a side of the transformer close to the second printed circuit board; and the second-type winding of the transformer extending from a side of the transformer away from the first and second printed circuit boards to the first or second printed circuit board.

[0007] In some embodiments, the first type of winding is a primary winding, and the second type of winding is a secondary winding.

[0008] In some embodiments, the first type of winding is a secondary winding, and the second type of winding is a primary winding.

[0009] In some embodiments, the first type winding and / or the second type winding includes at least one of the following: a copper sheet winding, a copper wire winding, a three-layer insulated wire winding, an enameled wire winding, and a film-covered wire winding.

[0010] In some embodiments, when the first type winding is a copper sheet winding, the lead ends of the copper sheet winding are soldered to the first printed circuit board and / or the second printed circuit board.

[0011] In some embodiments, at least one first support column is provided between the transformer and the first printed circuit board, so that a first gap is maintained between the body of the transformer and the first printed circuit board; at least one second support column is provided between the transformer and the second printed circuit board, so that a second gap is maintained between the body of the transformer and the second printed circuit board.

[0012] In some embodiments, the electric energy conversion device further includes a plurality of first power devices coupled to the at least one group of first type windings, and the plurality of first power devices are distributed on the first printed circuit board and the second printed circuit board to balance the power of the first printed circuit board and the second printed circuit board.

[0013] In some embodiments, the electric energy conversion device further includes a second power device coupled to the second type winding; wherein, when the second type winding of the transformer is led out to the first printed circuit board, the second power device is arranged on the first printed circuit board; when the second type winding of the transformer is led out to the second printed circuit board, the second power device is arranged on the second printed circuit board.

[0014] In some embodiments, the first power device includes at least one of the following: a rectifier device, a filter device, and a detection device.

[0015] In some embodiments, the electric energy conversion device further includes a fan, which is disposed on a side of the transformer and is configured to blow air toward the first printed circuit board, the second printed circuit board, the transformer, and the gap to dissipate heat.

[0016] An embodiment of the present application provides a power supply system, which includes a power supply and the power conversion device described in any one of the above embodiments, wherein the power conversion device is coupled to the power supply.

[0017] In the electric energy conversion device provided in an embodiment of the present application, the two first-type coils of each group of first-type windings of the transformer are respectively led to a first printed circuit board and a second printed circuit board. This improves heat dissipation compared to the current method of leading all transformer windings to a single printed circuit board. It also disperses the current originally concentrated on a single printed circuit board to two printed circuit boards, reducing the current stress on the printed circuit boards and making it more suitable for high-current applications. Furthermore, no additional processing steps are required for heat conduction and assembly, reducing assembly complexity. Furthermore, the gaps provided between the transformer body and the first and second printed circuit boards provide air flow space, accelerating the dissipation of heat generated by the power devices on the transformer and PCB (Printed Circuit Board) during operation to the environment (especially in high-frequency / high-power scenarios), significantly reducing the temperature rise of the transformer and PCB. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0019] Figure 1 It is a side view of a traditional electric energy conversion device.

[0020] Figure 2It is a top view of a traditional electric energy conversion device.

[0021] Figure 3 It is a front view of a traditional electric energy conversion device.

[0022] Figure 4 It is a front view of a traditional electric energy conversion device.

[0023] Figure 5 It is a side view of a transformer of an electric energy conversion device provided in one embodiment of the present application.

[0024] Figure 6 This is a side view of a transformer of an electric energy conversion device provided in one embodiment of the present application.

[0025] Figure 7 This is a schematic diagram of the structure of an electric energy conversion device provided in one embodiment of the present application.

[0026] Figure 8 This is a schematic diagram of the structure of an electric energy conversion device provided in one embodiment of the present application.

[0027] Figure 9 This is a circuit topology diagram of an electric energy conversion device provided in one embodiment of the present application.

[0028] Figure 10 It is a structural diagram of an electric energy conversion device provided in one embodiment of the present application.

[0029] Figure 11a This is a circuit topology diagram of a transformer of an electric energy conversion device provided in one embodiment of the present application.

[0030] Figure 11b Schematic diagram of the structure of the transformer of the electric energy conversion device provided in one embodiment of the present application.

[0031] Figure 12a This is a circuit topology diagram of a transformer of an electric energy conversion device provided in one embodiment of the present application.

[0032] Figure 12b Schematic diagram of the structure of the transformer of the electric energy conversion device provided in one embodiment of the present application.

[0033] Figure 13a This is a circuit topology diagram of a transformer of an electric energy conversion device provided in one embodiment of the present application.

[0034] Figure 13b Schematic diagram of the structure of the transformer of the electric energy conversion device provided in one embodiment of the present application.

[0035] Reference numerals

[0036] 100. Transformer;

[0037] 11. Magnetic core;

[0038] 12. Secondary winding;

[0039] 121. Secondary winding lead-out terminal;

[0040] 13. Primary winding;

[0041] 131. Primary winding lead-out terminal;

[0042] 14. Printed circuit boards;

[0043] 15. Power devices;

[0044] 16. Fan;

[0045] 17. Thermal conductive adhesive;

[0046] 200. Electric energy conversion equipment;

[0047] 1. A first printed circuit board;

[0048] 2. A second printed circuit board;

[0049] 3. Transformer;

[0050] 31. First type winding;

[0051] 311, lead-out terminal;

[0052] 32. Second type winding;

[0053] 321, lead-out terminal;

[0054] 33. Magnetic core;

[0055] 331. Open your mouth;

[0056] A. Gap;

[0057] B. Gap;

[0058] 4. The first power device;

[0059] 41. First output filter capacitor;

[0060] 42. Output current detection resistor;

[0061] 43. Output inductor;

[0062] 44. Output rectifier switch;

[0063] 45. Second output filter capacitor;

[0064] 4a. Primary side power supply filter circuit;

[0065] 4b, primary side power conversion circuit;

[0066] 4c, secondary side rectifier switch circuit;

[0067] 4d, secondary capacitor filter output circuit;

[0068] 51. Resonant capacitor;

[0069] 52. Resonant inductor;

[0070] 6. Fan;

[0071] 7. Output port. DETAILED DESCRIPTION

[0072] The following will be combined with the drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0073] The term "coupled (or connected)" used throughout the specification of the application (including the claims) may refer to any direct or indirect means of connection. For example, if the text describes a first device coupled (or connected) to a second device, it should be interpreted that the first device can be directly connected to the second device, or the first device can be indirectly coupled to the second device through other devices or some connection means. The terms "first", "second", etc. mentioned throughout the specification of this case (including the claims) are used to name components (element) and are not used to limit the upper or lower limit of the number of components, nor are they used to limit the order of components. In addition, whenever possible, components / members / steps with the same number in the drawings and embodiments represent the same or similar parts. Components / members / steps with the same number or the same terminology in different embodiments can refer to the relevant descriptions of each other.

[0074] In order to solve the above technical problems, the present application provides an electric energy conversion device. Figures 5 to 7As shown, the electric energy conversion device 200 provided in an embodiment of the present application includes: a first printed circuit board (PCB) 1 and a second PCB 2 arranged opposite to each other, and a transformer 3 arranged between the first PCB 1 and the second PCB 2; wherein gaps A and B are respectively defined between the body of the transformer 3 and the first PCB 1 and the second PCB 2; the transformer 3 includes: at least one group of first-type windings 31 and second-type windings 32, wherein each group of first-type windings 31 includes two first-type coils, one first-type coil is led out from a side of the transformer 3 close to the first PCB 1, and the other first-type coil is led out from a side of the transformer 3 close to the second PCB 2; the second-type winding 32 of the transformer 3 is led out from a side of the transformer 3 away from the first PCB 1 and the second PCB 2 to the first PCB 1 or the second PCB 2.

[0075] Specifically, the first-type winding 31 is a primary winding (Np), and the second-type winding 32 is a secondary winding (Ns). Alternatively, the first-type winding 31 is a secondary winding, and the second-type winding 32 is a primary winding. The magnetic core 33 of the transformer 3 couples energy from the primary winding of the transformer 3 and transfers it to the secondary winding of the transformer 3.

[0076] For the transformer 3, each primary winding may be led to the first printed circuit board 1 and the second printed circuit board 2, and the secondary winding may be led to one of the first printed circuit board 1 and the second printed circuit board 2; or each secondary winding may be led to the first printed circuit board 1 and the second printed circuit board 2 respectively, and the primary winding may be led to one of the first printed circuit board 1 and the second printed circuit board 2. In other words, the embodiment of the present application does not limit the type of winding of the transformer 3 that is simultaneously led to the first printed circuit board 1 and the second printed circuit board 2, and it may be a primary winding or a secondary winding. For example, for an electric energy conversion device 200 for low-voltage and high-current applications, each secondary winding of the transformer 3 may be led to the first printed circuit board 1 and the second printed circuit board 2 respectively, and the primary winding may be led to one of the first printed circuit board 1 and the second printed circuit board 2.

[0077] The first type winding 31 of the transformer 3 adopts an upper and lower outgoing wire structure, which can disperse the heat to the upper and lower sides of the transformer 3, so that the upper and lower sides of the transformer 3 can dissipate heat, which is better than the current one-side outgoing wire structure (see Figures 1 to 4 ), the heat dissipation effect will be better. In addition, an opening 331 can be provided on the side of the magnetic core 33 of the transformer 3 so that the second type winding 232 is led out from the opening 331.

[0078] In addition, gaps A and B are provided between the transformer body 3 and the first and second printed circuit boards 1 and 2, respectively. These gaps A and B provide space for airflow, accelerating the dissipation of heat generated by the transformer and the power devices on the PCBs during operation (especially in high-frequency / high-power scenarios), significantly reducing the temperature rise of the transformer and PCBs. The transformer body 3 refers to the physical body of the transformer, including the magnetic core, coil, and encapsulation casing (if any), but does not include the coil lead terminals.

[0079] A gap A between the body of the transformer 3 and the first printed circuit board 1 is at least 1 mm, and may be, for example, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 8 mm, 10 mm, 20 mm, 30 mm, etc. Similarly, a gap B between the body of the transformer 3 and the second printed circuit board 2 is at least 1 mm, and may be, for example, 1 mm, 2 mm, 3 mm, 5 mm, 7 mm, 9 mm, 10 mm, 20 mm, 30 mm, etc. The specific sizes of the gaps A and B may be determined according to factors such as the overall size, power, and heat dissipation conditions of the electric energy conversion device 200.

[0080] In this embodiment, the two first-type coils of each group of first-type windings 31 of the transformer 3 are respectively led to the first printed circuit board 1 and the second printed circuit board 2. In this way, compared with the current (see Figures 1 to 3 ) The method of leading each transformer winding to a printed circuit board 14 can increase heat dissipation and distribute the current originally concentrated on one printed circuit board to two printed circuit boards, reducing the current stress on the printed circuit boards and making it more suitable for high-current applications. Furthermore, no additional processing steps are required for heat conduction and assembly, reducing assembly complexity. In addition, the gaps provided between the main body of the transformer 3 and the first and second printed circuit boards 1 and 2 provide space for air flow, accelerating the dissipation of heat generated by the transformer and the power devices on the PCBs to the environment during operation (especially in high-frequency / high-power scenarios), significantly reducing the temperature rise of the transformer and the PCBs.

[0081] In some embodiments, the transformer 3 may be without a skeleton, and the first type winding 31 and the second type winding 32 are directly mounted on the center column of the transformer 3. Of course, the transformer 3 may also have a skeleton, and the embodiment of the present application does not limit the magnetic core 33 and the skeleton of the transformer 3.

[0082] In some embodiments, the first type winding 31 and / or the second type winding 32 includes at least one of the following: a copper sheet winding, a copper wire winding, a three-layer insulated wire winding, an enameled wire winding, and a film-covered wire winding.

[0083] like Figure 7As shown, in some embodiments, when the first-type winding 31 includes a copper sheet winding, the copper sheet winding lead-out end 311 can be soldered to the first printed circuit board 1 and / or the second printed circuit board 2. Specifically, when the first-type winding 31 includes a copper sheet winding, for the copper sheet winding extending to the first printed circuit board 1, the copper sheet winding lead-out end 311 can be soldered to the first printed circuit board 1, and for the copper sheet winding extending to the second printed circuit board 2, the copper sheet winding lead-out end 311 can be soldered to the second printed circuit board 2. Because the copper sheet winding and its lead-out end 311 have a certain degree of hardness, the copper sheet winding lead-out end 311 can maintain gaps A and B between the transformer 3 body and the first printed circuit board 1 and the second printed circuit board 2, respectively.

[0084] In some embodiments, at least one first support column (not shown) is disposed between the transformer 3 and the first printed circuit board 1 to maintain a first gap A between the transformer 3 body and the first printed circuit board 1; and at least one second support column (not shown) is disposed between the transformer 3 and the second printed circuit board 2 to maintain a second gap B between the transformer 3 body and the second printed circuit board 2. Specifically, to maintain gaps between the transformer 3 body and the first printed circuit board 1 and the second printed circuit board 2, respectively, especially when the first-type winding 31 is a flexible wire winding such as a copper wire winding, a triple-insulated wire winding, an enameled wire winding, or a film-coated wire winding, support columns may be disposed between the transformer 3 and the first printed circuit board 1, and between the transformer 3 and the second printed circuit board 2, respectively.

[0085] like Figure 8 As shown, in some embodiments, the electric energy conversion device 200 further includes a plurality of first power devices 4 coupled to the at least one group of first-type windings 31. The plurality of first power devices 4 are distributed on the first printed circuit board 1 and the second printed circuit board 2 to ensure power balance between the first printed circuit board 1 and the second printed circuit board 2. This facilitates uniform heat dissipation between the two printed circuit boards.

[0086] In some embodiments, the electric energy conversion device 200 further includes a second power device (not shown) coupled to the second type winding 32; wherein, when the second type winding 32 of the transformer 3 is led out to the first printed circuit board 1, the second power device is arranged on the first printed circuit board 1; when the second type winding 32 of the transformer 3 is led out to the second printed circuit board 2, the second power device is arranged on the second printed circuit board 2.

[0087] In some embodiments, the power device coupled to the first type winding 31 / the second type winding 32 includes at least one of the following: a rectifier device, a filter device, and a detection device. Figure 9 As shown, the electric energy conversion device 200 includes a primary power supply filter circuit 4a, a primary power conversion circuit 4b, a transformer 3, a secondary rectifier switch circuit 4c and a secondary capacitor filter output circuit 4d connected in sequence, wherein the primary power supply filter circuit 4a and the secondary capacitor filter output circuit 4d respectively include filter devices, and the secondary rectifier switch circuit 4c includes a rectifier device.

[0088] like Figure 8 and Figure 10 As shown, in some embodiments, when the first-type winding 31 is an output winding and the second-type winding 32 is an input winding, the first power device 4 coupled to the first-type winding 31 includes at least one of the following: a first output filter capacitor 41, an output current detection resistor 42, an output inductor 43, an output rectifier switch 44, and a second output filter capacitor 45. The first output filter capacitor 41 can be disposed on the first printed circuit board 1, and the output current detection resistor 42, the output inductor 43, the output rectifier switch 44, and the second output filter capacitor 45 can be disposed on the second printed circuit board 2.

[0089] like Figure 10 As shown, in some embodiments, when the first-type winding 31 is an output winding and the second-type winding 32 is an input winding, the second power device coupled to the second-type winding 32 may include at least one of the following: a resonant capacitor 51 and a resonant inductor 52. The resonant capacitor 51 and the resonant inductor 52 may be provided on the first printed circuit board 1.

[0090] like Figure 8 As shown, in some embodiments, the electric energy conversion device 200 further includes a fan 6, which is disposed on the side of the transformer 3. The fan 6 is configured to blow air toward the first printed circuit board 1, the second printed circuit board 2, the transformer 3, and the gaps A and B to dissipate heat. Specifically, the provision of the fan 6 allows the first printed circuit board 1, the second printed circuit board 2, and the transformer 3 to dissipate heat simultaneously, making heat dissipation more efficient without the need for additional thermal adhesive or a heat sink.

[0091] In some embodiments, the transformer 3 may have one or two groups (see Figure 11a and Figure 11b ), 3 groups (see Figure 12a and Figure 12b ), ..., or N groups (see Figure 13a and Figure 13b) first type windings 31, each group of first type windings 31 includes two first type windings 31, for example, when the first type windings 31 are copper sheet windings, a group of first type windings 31 includes two copper sheet windings.

[0092] In some embodiments, the electric energy conversion device 200 may be a DC-DC power converter for DC-DC power conversion.

[0093] Based on the same inventive concept, an embodiment of the present application further provides a power supply system, which includes a power supply and the electric energy conversion device described in any of the above embodiments, and the electric energy conversion device is coupled to the power supply.

[0094] The working principle and beneficial effects of the power supply system can be referred to the description of the above embodiments and will not be repeated here.

[0095] In the description of this specification, reference to the terms "one embodiment," "a specific embodiment," "some embodiments," "for example," "example," "specific example," 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 application. In this specification, the schematic representations 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 appropriate manner in any one or more embodiments or examples.

[0096] The specific embodiments described above further illustrate the purpose, technical solutions and beneficial effects of the present application. It should be understood that the above description is only a specific embodiment of the present application and is not intended to limit the scope of protection of the present application. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present application should be included in the scope of protection of the present application.

Claims

1. An electric energy conversion device, characterized in that: The electric energy conversion device includes a first printed circuit board and a second printed circuit board arranged opposite to each other, and also includes a transformer arranged between the first printed circuit board and the second printed circuit board; wherein, There are gaps between the transformer body and the first printed circuit board and the second printed circuit board respectively; The transformer comprises: at least one group of first-type windings and second-type windings, wherein each group of first-type windings comprises two first-type coils, one first-type coil is led out from a side of the transformer close to the first printed circuit board, and the other first-type coil is led out from a side of the transformer close to the second printed circuit board; The second type winding of the transformer is led out from a side of the transformer away from the first printed circuit board and the second printed circuit board to the first printed circuit board or the second printed circuit board.

2. The electric energy conversion device according to claim 1, characterized in that: The first type of winding is a primary winding, and the second type of winding is a secondary winding.

3. The electric energy conversion device according to claim 1, characterized in that: The first type of winding is a secondary winding, and the second type of winding is a primary winding.

4. The electric energy conversion device according to claim 2 or 3, characterized in that: The first type winding and / or the second type winding includes at least one of the following: a copper sheet winding, a copper wire winding, a three-layer insulated wire winding, an enameled wire winding, and a film-covered wire winding.

5. The electric energy conversion device according to claim 4, characterized in that: When the first type of winding is a copper sheet winding, the lead end of the copper sheet winding is welded to the first printed circuit board and / or the second printed circuit board.

6. The electric energy conversion device according to claim 1, characterized in that: At least one first support column is provided between the transformer and the first printed circuit board, so that a first gap is maintained between the body of the transformer and the first printed circuit board; At least one second supporting column is provided between the transformer and the second printed circuit board, so that a second gap is maintained between the body of the transformer and the second printed circuit board.

7. The electric energy conversion device according to claim 1, characterized in that: The electric energy conversion device further includes a plurality of first power devices coupled to the at least one group of first type windings, wherein the plurality of first power devices are distributed on the first printed circuit board and the second printed circuit board to balance power between the first printed circuit board and the second printed circuit board.

8. The electric energy conversion device according to claim 1, characterized in that: The electric energy conversion device further includes a second power device coupled to the second type winding; wherein, When the second type winding of the transformer is led out to the first printed circuit board, the second power device is arranged on the first printed circuit board; When the second type winding of the transformer is led out to the second printed circuit board, the second power device is arranged on the second printed circuit board.

9. The electric energy conversion device according to claim 7, characterized in that: The first power device includes at least one of the following: a rectifier device, a filter device, and a detection device.

10. The electric energy conversion device according to any one of claims 7 to 8, characterized in that: The electric energy conversion device further includes a fan, which is disposed on a side of the transformer and is configured to blow air toward the first printed circuit board, the second printed circuit board, the transformer, and the gap to dissipate heat.

11. A power supply system, characterized in that: The invention comprises a power source and the electric energy conversion device according to any one of claims 1 to 10, wherein the electric energy conversion device is coupled to the power source.

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