Integrated transformer with dynamic magnetic flux adjusting function

Abstract

The invention discloses an integrated transformer with a dynamic magnetic flux adjusting function, and belongs to the technical field of transformers. The packaging shell is fixedly arranged on the substrate, and a sealed mounting cavity is defined by the packaging shell and the substrate; the magnetic core assembly is arranged in the sealed mounting cavity and comprises two magnetic core bodies which are oppositely arranged in the axial direction and an elastic supporting piece, the central areas of the two magnetic core bodies are oppositely combined to form a central magnetic column, a variable air gap is formed between the edge areas, and the elastic supporting piece is connected with the magnetic core bodies and the substrate or the packaging shell; the elastic reset device is used for enabling the magnetic core body to float in the axial direction and achieve elastic reset. The planar spiral coil is fixedly arranged on the substrate, is arranged between the internal gaps of the two magnetic core bodies, and is coaxially arranged around the central magnetic column; the magnetic flux adjusting mechanism is arranged on the peripheral side of the magnetic core assembly in a surrounding mode. According to the transformer, continuous dynamic adjustment of working magnetic flux can be achieved, the multiple sets of piezoelectric ceramic pieces which are evenly arranged in the circumferential direction enable the magnetic core body to be stressed in a balanced mode, movement is stable, and deflection and clamping stagnation of the magnetic core body are effectively avoided.

Description

Technical Field

[0001] This invention relates to the field of transformer technology, and more specifically to an integrated transformer with dynamic flux regulation function. Background Technology

[0002] Integrated transformers, as core passive components in power electronic systems, are widely used in miniaturized power integration scenarios with stringent requirements for size and weight, such as portable electronic devices, wearable devices, and power modules, thanks to their compact structure, high integration, and excellent heat dissipation performance.

[0003] Currently, mainstream integrated planar transformers still primarily use a fixed air-gap core design. Their operating magnetic flux characteristics are fixed, making it difficult to adaptively and dynamically adjust according to operating conditions such as input voltage fluctuations and load changes. This results in low efficiency and easy core saturation in a wide operating range, limiting their applicability. Existing few transformer solutions that attempt to achieve adjustable air gaps mostly adopt single-sided or single-point drive modes, resulting in uneven circumferential force on the core, which can easily lead to tilting, jamming, and uneven wear, making it difficult to guarantee the accuracy of air gap adjustment.

[0004] To address these issues, an integrated transformer with dynamic flux regulation function is provided. Summary of the Invention

[0005] The purpose of this invention is to provide an integrated transformer with dynamic magnetic flux adjustment function, which solves the problem that existing integrated transformers are difficult to dynamically adjust magnetic flux.

[0006] The present invention achieves the above objectives through the following technical solutions: An integrated transformer with dynamic flux regulation function includes: substrate; The encapsulation shell is fixedly disposed on the substrate and forms a sealed mounting cavity with the substrate; The magnetic core assembly, located within the sealed mounting cavity, includes two magnetic cores arranged axially opposite each other and an elastic support member. The central regions of the two magnetic cores are joined to form a central magnetic column, and a variable air gap is formed between the edge regions. The elastic support member connects the magnetic cores to the substrate or the package shell, enabling the magnetic cores to float axially and achieve elastic reset. A planar helical coil is fixed on the substrate and disposed between the internal gaps of the two magnetic cores, and is coaxially arranged around the central magnetic column; A magnetic flux adjustment mechanism is arranged around the periphery of the magnetic core assembly to drive the two magnetic cores to move relative to each other along the axial direction, thereby adjusting the size of the variable air gap and realizing dynamic adjustment of the magnetic flux.

[0007] As a further optimization of the present invention, a first guide ring is fixedly provided on the substrate, and the first guide ring is sleeved on the outer periphery of one of the magnetic cores; a second guide ring is fixedly provided on the inner top surface of the encapsulation shell, and the second guide ring is sleeved on the outer periphery of the other magnetic core.

[0008] As a further optimization of the present invention, the elastic support is configured as an elastic support sheet, and the elastic support sheet is provided in multiple forms and evenly distributed along the circumference of the magnetic core.

[0009] As a further optimization of the present invention, the magnetic flux adjustment mechanism includes a plurality of piezoelectric ceramic sheets evenly distributed along the circumference of the magnetic core assembly and a mounting ring for fixing the piezoelectric ceramic sheets; a wedge is fixedly provided on the side of the piezoelectric ceramic sheet facing the magnetic core assembly, and the wedge is provided with a first inclined surface and a second inclined surface arranged opposite to each other, the first inclined surface slidingly engaging with the mating surface of one of the magnetic core bodies, and the second inclined surface slidingly engaging with the mating surface of the other magnetic core body.

[0010] As a further optimization of the present invention, a wedge-shaped groove is provided on the magnetic core at the position corresponding to the wedge block, and the wedge block slides in conjunction with the wedge groove.

[0011] As a further optimization of the present invention, each of the piezoelectric ceramic sheets is independently controlled; all the piezoelectric ceramic sheets move synchronously to drive the two magnetic cores to move axially as a whole, so as to adjust the size of the variable air gap; the piezoelectric ceramic sheets in different positions move differentially to drive the two magnetic cores to generate angular deflection, so as to correct the attitude and parallelism of the magnetic cores.

[0012] As a further optimization of the present invention, the magnetic flux adjustment mechanism further includes an oil-lubricating structure; the oil-lubricating structure includes an oil storage cavity opened inside the wedge block, and a plurality of capillary micropores opened on the sliding inclined surface of the wedge block in contact with the wedge groove; the capillary micropores are connected to the oil storage cavity, and the oil storage cavity is filled with insulating lubricating oil.

[0013] As a further optimization of the present invention, the oil seepage lubrication structure further includes an oil groove formed on the inclined surface of the wedge-shaped groove; the oil groove and the capillary micropore are aligned or misaligned during the sliding process to realize the on / off control of the oil circuit; at least one set of oil grooves is provided along the inclined direction of the wedge-shaped groove.

[0014] The beneficial effects of this invention are as follows: 1. This invention enables continuous dynamic adjustment of the working magnetic flux. The multiple sets of piezoelectric ceramic sheets arranged evenly in the circumference ensure that the magnetic core is subjected to balanced force and moves smoothly, effectively avoiding the magnetic core from tilting and jamming.

[0015] 2. The micro-oil permeation lubrication structure of the present invention can form a stable lubricating film at the sliding interface, eliminate the stick-slip effect, ensure smooth transmission and displacement accuracy, thereby ensuring adjustment accuracy, and achieve maintenance-free operation, which is suitable for the use requirements of sealed integrated transformers. Attached Figure Description

[0016] Figure 1 Exploded view of the overall structure of the present invention Figure 1 ; Figure 2 Exploded view of the overall structure of the present invention Figure 2 ; Figure 3 This is a cross-sectional view of the overall structure of the present invention; Figure 4 This is a schematic diagram of the magnetic flux adjustment mechanism of the present invention; Figure 5 This is a schematic diagram of the magnetic flux adjustment mechanism of the present invention; Figure 6 This is a schematic diagram of the oil-lubricating structure of the present invention.

[0017] In the picture: 1. Substrate; 101. First guide ring; 2. Encapsulation shell; 201. Second guide ring; 3. Magnetic core; 301. Elastic support sheet; 302. Wedge groove; 303. Oil groove; 4. Planar spiral coil; 5. Magnetic flux adjustment mechanism; 501. Piezoelectric ceramic sheet; 502. Mounting ring; 503. Wedge block; 504. Capillary micropore; 505. Oil reservoir. Detailed Implementation

[0018] The present application will now be described in further detail with reference to the accompanying drawings. It should be noted that the following specific embodiments are only used to further illustrate the present application and should not be construed as limiting the scope of protection of the present application. Those skilled in the art can make some non-essential improvements and adjustments to the present application based on the above application content.

[0019] Example 1 To address the challenge of dynamically adjusting magnetic flux in existing integrated transformers, please refer to [link / reference]. Figures 1-3 The present invention provides an integrated transformer with dynamic magnetic flux regulation function. The integrated transformer has a flat block shape and includes: Substrate 1, such as PCB or ceramic plate, has pads underneath, which are directly soldered onto the circuit board; The outer casing 2 is fixedly disposed on the substrate 1 and forms a sealed mounting cavity with the substrate 1; The magnetic core assembly, located in a sealed mounting cavity, includes two magnetic core bodies 3 arranged axially opposite each other and an elastic support member. The central regions of the two magnetic core bodies 3 are joined to form a central magnetic column, and a variable air gap is formed between the edge regions. The elastic support member connects the magnetic core bodies 3 to the substrate 1 or the package shell 2, so that the magnetic core bodies 3 can float axially and achieve elastic reset. The planar spiral coil 4 is fixed on the substrate 1 and located between the internal gaps of the two magnetic cores 3, and is coaxially arranged around the central magnetic post. Specifically, the planar spiral coil 4 is constructed using printed circuit board technology, and its interior integrates primary windings and secondary windings that are stacked along the axial direction. The magnetic flux adjustment mechanism 5 is arranged around the periphery of the magnetic core assembly and is used to drive the two magnetic cores 3 to move relative to each other along the axial direction in order to adjust the size of the variable air gap and realize the dynamic adjustment of the magnetic flux.

[0020] In use, an external control signal acts on the magnetic flux adjustment mechanism 5, driving the mechanism to produce mechanical action, forcing the two magnetic cores 3 to overcome the resistance of the elastic support and move relative to each other along the axial direction, thereby changing the size of the variable air gap between the edges of the magnetic cores 3, and thus dynamically adjusting the magnetic flux passing through the planar spiral coil 4 and the central magnetic column; when reset is required, the driving force is removed, and the magnetic cores 3 are reset under the action of the elastic support.

[0021] In addition, a first guide ring 101 is fixedly provided on the substrate 1. The first guide ring 101 is sleeved on the outer periphery of one of the magnetic cores 3 to restrict the radial degree of freedom of the magnetic core 3 and guide its axial movement. A second guide ring 201 is fixedly provided on the inner top surface of the package shell 2. The second guide ring 201 is sleeved on the outer periphery of the other magnetic core 3 to restrict the radial degree of freedom of the magnetic core 3 and guide its axial movement.

[0022] Specifically, the elastic support is configured as an elastic support sheet 301. Multiple elastic support sheets 301 are provided and evenly distributed along the circumference of the magnetic core 3. One end of each elastic support sheet 301 is fixedly connected to the corresponding magnetic core 3, and the other end is fixedly connected to the substrate 1 or the package shell 2. The elastic deformation of the support sheet provides a restoring force and allows axial displacement.

[0023] Specifically, such as Figures 4-5 As shown, the magnetic flux adjustment mechanism 5 includes multiple piezoelectric ceramic sheets 501 evenly distributed circumferentially along the magnetic core assembly and a mounting ring 502 for fixing the piezoelectric ceramic sheets 501. A wedge 503 is fixedly mounted on the side of the piezoelectric ceramic sheet 501 facing the magnetic core assembly. The wedge 503 has a first inclined surface and a second inclined surface arranged opposite to each other. The first inclined surface slides in contact with the mating surface of one of the magnetic core bodies 3, and the second inclined surface slides in contact with the mating surface of the other magnetic core body 3. A wedge-shaped groove 302 is formed on the magnetic core body 3 at the position corresponding to the wedge 503, and the wedge 503 slides in contact with the wedge-shaped groove 302.

[0024] After being powered on, the piezoelectric ceramic sheet 501 undergoes expansion and contraction deformation, driving the wedge block 503 to move within the wedge groove 302, simultaneously opening the two magnetic cores 3. The elastic support sheet 301 undergoes elastic deformation. When the driving force is removed from the piezoelectric ceramic sheet 501, the elastic support sheet 301, under its own elastic action, drives the magnetic cores 3 to reset and close, thereby realizing dynamic adjustment and automatic reset of the air gap size.

[0025] Example 2 Based on Example 1, in order to achieve active parallelism correction of the two magnetic cores 3 and offset the skewing caused by assembly errors, external stress and vibration, each piezoelectric ceramic sheet 501 is independently controlled; all piezoelectric ceramic sheets 501 move synchronously to drive the two magnetic cores 3 to move axially as a whole to adjust the size of the variable air gap; the piezoelectric ceramic sheets 501 in different positions move differentially to drive the two magnetic cores 3 to generate angular deflection to correct the attitude and parallelism of the magnetic cores 3.

[0026] Under independent drive control, each piezoelectric ceramic sheet 501 can synchronously generate telescopic displacement, and synchronously drive the two magnetic cores 3 to move axially through the wedge block 503 to achieve uniform adjustment of the air gap size. Alternatively, the piezoelectric ceramic sheets 501 in different positions can generate differential displacement, driving the wedge block 503 at the corresponding position to form different extension amounts, thereby correcting the posture of the magnetic core 3 in real time, ensuring that the magnetic core 3 always remains parallel, eliminating skewness and jamming, and offsetting skewness caused by assembly errors, external stress, and vibration.

[0027] It should be noted that, in specific implementation, those skilled in the art can select a suitable high-voltage drive power supply and control system, provided that the above-mentioned usage requirements are met. For example, they can select a high-voltage amplifier with corresponding output specifications and a microprocessor unit with multi-channel independent control function. Given that the hardware architecture, signal processing logic and drive algorithm of such high-voltage drive modules and industrial controllers are all well-known mature technologies in the field, their specific working principles and internal structures will not be described in detail here.

[0028] Example 3 Based on Embodiments 1 and 2, in order to solve the problem of wear and friction instability caused by the long-term movement of the wedge block 503 and the magnetic core 3, and to ensure smooth transmission and adjustment accuracy, such as Figures 4-6As shown, the magnetic flux adjustment mechanism 5 also includes an oil-lubricating structure; the oil-lubricating structure includes an oil storage cavity 505 opened inside the wedge block 503, and a plurality of capillary micropores 504 opened on the sliding inclined surface where the wedge block 503 contacts the wedge groove 302; the capillary micropores 504 are connected to the oil storage cavity 505, and the lubricating oil only acts on the sliding mating surface and does not leak into the area of ​​the planar spiral coil 4. The oil storage cavity 505 is filled with insulating lubricating oil, which is an electrically insulating high-temperature resistant lubricating oil that does not affect the insulation performance and electromagnetic performance of the transformer.

[0029] During the relative sliding process between the wedge block 503 and the magnetic core 3, the lubricating oil is continuously and evenly seeped into the friction interface through capillary action, forming a stable lubricating film, eliminating the stick-slip effect, ensuring smooth and stable inclined plane transmission, and thus ensuring displacement accuracy.

[0030] To further improve the lubrication effect, the oil seepage lubrication structure also includes an oil groove 303 opened on the inclined surface of the wedge groove 302; the oil groove 303 and the capillary micropore 504 are aligned or misaligned during the sliding process to realize the on / off control of the oil circuit; at least one set of oil grooves 303 is provided along the inclined direction of the wedge groove 302.

[0031] The lubrication process is as follows: when the outlet of the capillary micro-orifice 504 on the wedge 503 is directly opposite the smooth solid area of ​​the inner wall of the wedge groove 302, that is, the capillary micro-orifice 504 is misaligned with the oil groove 303, the lubricating oil in the oil reservoir 505 cannot seep out because the solid metal surface tightly seals the outlet of the capillary micro-orifice 504, achieving zero-leakage standby and eliminating the risk of oil spillage; when the piezoelectric ceramic plate 501 drives the wedge 503 to move to a specific working range or a specific stroke point for each action, the outlet of the capillary micro-orifice 504 is precisely aligned with the oil groove. At point 303, the outlet of the capillary micropore 504 connects with the cavity formed by the oil groove 303, and the seal is released. Under the action of capillary force, a small amount of lubricating oil in the oil storage cavity 505 is injected into the oil groove 303. As the piezoelectric ceramic plate 501 continues to drive the wedge block 503 to reciprocate, the lubricating oil injected into the oil groove 303, under the combined action of shear force and surface tension, quickly spreads along the inclined plane and fills the entire sliding contact interface between the wedge block 503 and the wedge groove 302, forming a uniform and stable oil film, thereby achieving efficient lubrication.

[0032] The embodiments described above are merely examples of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

Claims

1. An integrated transformer with dynamic flux regulation function, characterized in that, include: substrate(1); The outer casing (2) is fixedly disposed on the substrate (1) and forms a sealed mounting cavity with the substrate (1); The magnetic core assembly, located in the sealed mounting cavity, includes two magnetic cores (3) arranged opposite each other along the axial direction and an elastic support member. The central regions of the two magnetic cores (3) are joined to form a central magnetic column, and a variable air gap is formed between the edge regions. The elastic support member connects the magnetic cores (3) to the substrate (1) or the package shell (2) to enable the magnetic cores (3) to float along the axial direction and achieve elastic reset. A planar spiral coil (4) is fixed on the substrate (1) and located between the internal gaps of the two magnetic cores (3), and is coaxially arranged around the central magnetic column; A magnetic flux adjustment mechanism (5) is arranged around the periphery of the magnetic core assembly to drive the two magnetic cores (3) to move relative to each other along the axial direction in order to adjust the size of the variable air gap and realize the dynamic adjustment of magnetic flux.

2. An integrated transformer with dynamic flux regulation function according to claim 1, characterized in that, A first guide ring (101) is fixedly provided on the substrate (1), and the first guide ring (101) is sleeved on the outer periphery of one of the magnetic cores (3); A second guide ring (201) is fixedly provided on the inner top surface of the encapsulation shell (2), and the second guide ring (201) is sleeved on the outer periphery of another magnetic core (3).

3. An integrated transformer with dynamic flux regulation function according to claim 1, characterized in that, The elastic support is configured as an elastic support sheet (301), and the elastic support sheet (301) has multiple sheets that are evenly distributed along the circumference of the magnetic core (3).

4. An integrated transformer with dynamic flux regulation function according to claim 1, characterized in that, The magnetic flux adjustment mechanism (5) includes a plurality of piezoelectric ceramic sheets (501) evenly distributed along the circumference of the magnetic core assembly and a mounting ring (502) for fixing the piezoelectric ceramic sheets (501). The piezoelectric ceramic sheet (501) is fixedly provided with a wedge (503) on the side facing the magnetic core assembly. The wedge (503) is provided with a first inclined surface and a second inclined surface that are arranged opposite to each other. The first inclined surface slides in contact with the mating surface of one of the magnetic cores (3), and the second inclined surface slides in contact with the mating surface of the other magnetic core (3).

5. An integrated transformer with dynamic flux regulation function according to claim 4, characterized in that, A wedge-shaped groove (302) is provided on the magnetic core (3) at the position corresponding to the wedge block (503), and the wedge block (503) slides in conjunction with the wedge-shaped groove (302).

6. An integrated transformer with dynamic flux regulation function according to claim 4, characterized in that, Each of the piezoelectric ceramic sheets (501) is independently controlled; All the piezoelectric ceramic sheets (501) move synchronously to drive the two magnetic cores (3) to translate axially as a whole to adjust the size of the variable air gap; The piezoelectric ceramic sheet (501) in different positions operates differentially to drive the two magnetic cores (3) to generate angular deflection in order to correct the attitude and parallelism of the magnetic cores (3).

7. An integrated transformer with dynamic flux regulation function according to claim 5, characterized in that, The magnetic flux adjustment mechanism (5) also includes an oil-lubricating structure; The oil-lubricating structure includes an oil storage cavity (505) inside the wedge (503) and a plurality of capillary micropores (504) on the sliding inclined surface of the wedge (503) in contact with the wedge groove (302). The capillary micropores (504) are connected to the oil storage cavity (505), which is filled with insulating lubricating oil.

8. An integrated transformer with dynamic flux regulation function according to claim 7, characterized in that, The oil-lubricating structure also includes an oil groove (303) formed on the inclined surface of the wedge groove (302). The oil groove (303) and the capillary micropore (504) are aligned or misaligned during the sliding process to achieve the on / off control of the oil circuit; At least one set of oil tanks (303) is provided along the inclined direction of the wedge groove (302).

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