Modular winding stacked transformer

Abstract

The application discloses a modular winding stack type transformer, and relates to the technical field of automobile electronic power conversion and vehicle-mounted power module technology, and comprises a magnetic core provided with a magnetic core column; at least two winding combinations are arranged in an axial stacking mode along the magnetic core column, and each winding combination is sleeved on the magnetic core column; wherein each winding combination comprises a secondary side copper sheet, a framework and a winding wire, the secondary side copper sheet is fixedly connected with the framework and forms a winding shaft, the winding wire is wound on the winding shaft, the framework is provided with a nesting structure for forming axial stacking limiting with the framework of another adjacent winding combination, and the secondary side copper sheet is provided with a heat dissipation part extending outward beyond the outer edge of the winding wire for increasing the heat dissipation effect. The transformer can realize flexible combination of windings to adapt to different voltage requirements, simultaneously simplify the fixing structure between the windings and optimize the internal heat dissipation path.

Description

Technical Field

[0001] This invention relates to the field of automotive electronic power conversion and on-board power modular technology, and more specifically, to a modular winding stacked transformer. Background Technology

[0002] In the on-board power system of new energy vehicles, the transformer is a core component of the OBC (On-Board Charger) and DC-DC converter, playing a crucial role in voltage conversion and isolated power transmission. The transformer transmits power based on the law of electromagnetic induction. When the primary winding is connected to the input voltage, it generates an alternating magnetic field, which is coupled to the secondary winding via the magnetic core. The secondary winding induces a voltage corresponding to the turns ratio, thus completing the conversion of power at different voltage levels. Traditional on-board transformers often use an integrated fixed design for the primary and secondary windings, which has the following shortcomings:

[0003] Firstly, the relative positions between windings are fixed, the winding combination is simple, and the primary-secondary turns ratio is fixed, making it impossible to flexibly adjust according to different voltage requirements. With the diversification of new energy vehicle models, the voltage level and power requirements of the power supply system show personalized differences. Traditional designs are difficult to adapt to the adaptation needs of different models. When the power supply system is upgraded or changed, it is often necessary to replace the entire transformer, resulting in high adaptation costs.

[0004] Secondly, in order to maintain the fixed position of each winding on the magnetic core, additional fixing structures or a large amount of adhesive are usually required for limiting and fastening. This not only increases the assembly process and material costs, but also occupies limited axial space, which is not conducive to the miniaturization design of transformers.

[0005] Third, the internal windings of traditional transformers are tightly fitted together, and the heat generated during the operation of the windings mainly relies on the conduction of the wires themselves and the frame, resulting in a long heat conduction path and low heat dissipation efficiency.

[0006] Therefore, how to achieve flexible combination of windings to adapt to different voltage requirements, while simplifying the fixing structure between windings and optimizing the internal heat dissipation path, is a problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0007] In view of this, the purpose of the present invention is to provide a modular winding stacked transformer that can realize flexible combination of windings to adapt to different voltage requirements, while simplifying the fixing structure between windings and optimizing the internal heat dissipation path.

[0008] To achieve the above objectives, the present invention provides the following technical solution:

[0009] A modular winding stacked transformer, comprising:

[0010] The magnetic core has a central column.

[0011] At least two winding combinations are stacked along the axial direction of the magnetic core column, and each winding combination is sleeved on the magnetic core column;

[0012] Each of the winding assemblies includes a secondary copper sheet, a bobbin, and a winding conductor. The secondary copper sheet is fixedly connected to the bobbin and forms a winding shaft. The winding conductor is wound around the winding shaft. The bobbin has a nested structure for axial stacking and limiting with the bobbin of another adjacent winding assembly. The secondary copper sheet has a heat dissipation portion extending beyond the outer edge of the winding conductor to increase heat dissipation.

[0013] Preferably, the skeleton includes a plate and a plurality of cantilever arms. The plate has a central hole through which the magnetic core column passes. The plurality of cantilever arms are disposed on the plate around the outer edge of the central hole and extend along the axial direction of the magnetic core column to be fixedly connected to the corresponding secondary copper sheet to form the winding shaft.

[0014] Preferably, a portion of the cantilever's outer peripheral wall is provided with an anti-retraction stop, which passes through the central hole of the secondary copper sheet and abuts against one side of the secondary copper sheet to prevent the secondary copper sheet from detaching from the frame; another portion of the cantilever's outer peripheral wall is provided with an extension stop, which abuts against the other side of the secondary copper sheet to limit the extension position of the secondary copper sheet along the installation direction.

[0015] Preferably, at least one of the cantilever arms is provided with an anti-rotation part, and the secondary copper plate is provided with a notch that matches the anti-rotation part. The anti-rotation part engages and limits the movement of the secondary copper plate relative to the frame.

[0016] Preferably, the nested structure includes a protrusion and a notch. The distal end of each cantilever is provided with the protrusion. The inner edge of the central hole of the skeleton is provided with a plurality of notches that correspond to and match the plurality of protrusions. In two adjacent winding assemblies, the protrusion of the skeleton of one winding assembly is engaged with the notch of the skeleton of the other winding assembly to form an axial stacking limit.

[0017] Preferably, a gap is left between two adjacent cantilever arms to form a first heat-conducting perforation on the heat-conducting path between the magnetic core column and the winding conductor; and / or, the plate of the skeleton is provided with a second heat-conducting perforation on the heat-conducting path between the secondary copper sheet and the winding conductor.

[0018] Preferably, the plate of the skeleton is provided with a guide groove that connects to the second heat-conducting perforation, for allowing heat-conducting adhesive to flow into the second heat-conducting perforation.

[0019] Preferably, in two adjacent winding assemblies, the skeleton of one winding assembly is arranged adjacent to the secondary copper sheet of the other winding assembly, such that the skeleton is spaced apart between any two adjacent secondary copper sheets.

[0020] Preferably, it further includes at least one additional secondary copper sheet, which is sleeved together with the winding assembly on the central column of the magnetic core, and the additional secondary copper sheet is disposed between two adjacent winding assemblies, with both sides of the additional secondary copper sheet being adjacent to the skeleton of the two adjacent winding assemblies respectively.

[0021] Preferably, the magnetic core includes a first magnetic core and a second magnetic core that are fastened together to form a clamping space. The heat dissipation portions of the secondary copper sheet and the additional secondary copper sheet both extend out of the clamping space. The magnetic core has an insulating plate at one end away from the heat dissipation portion. The insulating plate has through holes for the secondary copper sheet and the additional secondary copper sheet to pass through.

[0022] The modular winding stacked transformer provided by this invention stacks at least two winding combinations along the axial direction of the magnetic core column. Each winding combination serves as an independent functional unit, and its quantity or combination method can be flexibly increased or decreased or adjusted according to different voltage conversion requirements, thereby freely configuring the turns ratio. When the power system is upgraded or changed, there is no need to replace the entire transformer, reducing adaptation costs. At the same time, the nested structure on the frame allows adjacent winding combinations to directly form axial stacking limits, maintaining the relative positions of each winding combination on the magnetic core column without the need for additional independent fasteners or a large amount of adhesive. Furthermore, the nested structure is located on the frame and does not occupy additional axial space, which helps to achieve transformer miniaturization design.

[0023] Furthermore, the secondary copper sheet has a heat dissipation section extending beyond the outer edge of the winding conductor. Utilizing the high thermal conductivity of copper, the heat generated during operation within the winding assembly is directly conducted to the outside of the winding, shortening the heat conduction path and effectively reducing winding temperature rise. The extension of the heat dissipation section beyond the outer edge of the winding allows heat to dissipate to the surrounding environment more quickly, improving heat dissipation efficiency. Additionally, each winding assembly has a pre-integrated secondary copper sheet and winding conductor within a frame, forming a complete primary and secondary functional unit. Assembly simply involves stacking the pre-fabricated winding assemblies sequentially onto the magnetic core pillar, eliminating the need for complex winding and insulation processes during assembly, thus improving assembly efficiency and product consistency.

[0024] In summary, this invention, through modular winding combinations, combined with the nested structure of the skeleton and the heat dissipation part of the secondary copper sheet, can achieve flexible configuration of transformer turns ratio, simplification of the fixing structure, improvement of heat dissipation performance and improvement of assembly efficiency. It is suitable for application scenarios with high requirements for space, heat dissipation and flexibility, such as on-board chargers for new energy vehicles and DC-DC converters. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0026] Figure 1 A schematic diagram of a modular winding stacked transformer provided by the present invention from one perspective;

[0027] Figure 2 Another structural schematic diagram of a modular winding stacked transformer provided by the present invention;

[0028] Figure 3 An exploded view of a modular winding stacked transformer provided by the present invention;

[0029] Figure 4 A schematic diagram of the engagement structure on the skeleton used for fixed connection with the secondary copper sheet;

[0030] Figure 5 A schematic diagram from one perspective showing the fixed connection between the skeleton and the secondary copper sheet in the winding assembly;

[0031] Figure 6 Another perspective schematic diagram showing the fixed connection between the skeleton and the secondary copper sheet in the winding assembly;

[0032] Figure 7 A schematic diagram showing the axial stacking and limiting of a skeleton of one winding assembly and a skeleton of another winding assembly;

[0033] Figure 8 A schematic diagram of a nested structure used for axial stacking and limiting between two adjacent skeletons;

[0034] Figure 9 A schematic diagram of setting the first heat-conducting cutout for the skeleton;

[0035] Figure 10 A schematic diagram showing the second heat-conducting perforation for the skeleton;

[0036] Figure 11 A schematic diagram of setting guide grooves for the skeleton;

[0037] Figure 12 A schematic diagram of the wiring structure for the skeleton;

[0038] Figure 13 This is a schematic diagram showing the installation of two opposing magnetic cores and all the windings.

[0039] Figure 14for Figure 13 Partial breakdown diagram of the structure at point A;

[0040] Figure 15 A schematic diagram of clamping all winding combinations for two opposing magnetic cores.

[0041] Figure label:

[0042] 1-Magnetic core; 2-Winding assembly; 3-Additional secondary copper sheet; 4-Insulating board; 5-Wire management frame;

[0043] 11-Core center post;

[0044] 21-Secondary copper sheet; 22-Board; 23-Winding conductor;

[0045] 211 - Heat dissipation section; 212 - Center hole of copper plate; 213 - Notch;

[0046] 221-Plate body; 222-Cantilever; 223-Skeleton center hole; 224-Anti-reverse stop; 225-Extension stop; 226-Anti-rotation part; 227-Protrusion; 228-Notch; 229-First heat-conducting perforation; 2210-Second heat-conducting perforation; 2211-Guide groove; 2212-Wire arrangement structure;

[0047] 231 - Lead-out line;

[0048] 41-Perforation. Detailed Implementation

[0049] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0050] The core of this invention is to provide a modular winding stacked transformer that enables flexible combination of windings to adapt to different voltage requirements, while simplifying the fixing structure between windings and optimizing the internal heat dissipation path.

[0051] It should be noted that in this embodiment, the orientation or positional relationship indicated by "up", "down", "left", "right", etc. is based on the orientation or positional relationship shown in the accompanying drawings. It is only for the convenience of describing this application and simplifying the description, and is not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation on this application.

[0052] Please refer to Figure 3This embodiment provides a modular winding stacked transformer, including a magnetic core 1 and at least two winding combinations 2.

[0053] The magnetic core 1 has a core post 11. In this embodiment, the magnetic core 1 is a PQ type magnetic core, including a first magnetic core and a second magnetic core, which are fastened together to form the core post 11. It should be noted that the specific model of the magnetic core 1 is not limited to the PQ type, and other types of magnetic cores can be selected according to actual needs.

[0054] At least two winding assemblies 2 are stacked along the axial direction of the core column 11, with each winding assembly 2 fitted onto the core column 11. The specific number of winding assemblies 2 can be determined according to the required turns ratio parameters of the transformer. This embodiment uses three winding assemblies as an example for illustration, but it is not limited to this. In practical applications, more winding assemblies can be set as needed.

[0055] like Figure 3 As shown, each winding assembly 2 includes a secondary copper sheet 21, a bobbin 22, and a winding conductor 23. The secondary copper sheet 21 is fixedly connected to the bobbin 22, and the two together form a winding shaft. The winding conductor 23 is wound around the winding shaft. In this embodiment, the winding conductor 23 is an insulated conductor with its own insulation sheath or an insulated self-adhesive wire, which can be directly wound onto the winding shaft without the need for an additional insulation layer. In particular, the winding conductor 23 can be tightly wound onto the winding shaft without the need for pre-winding into a toroidal coil, which helps to reduce the size of the winding shaft, indirectly reducing the size of the entire device and increasing the power density. Furthermore, since no self-adhesive layer is required, the cost of the winding assembly can be significantly reduced.

[0056] The frame 22 is provided with a nested structure for axial stacking and limiting with the frame 22 of another adjacent winding assembly 2. Specifically, when two winding assemblies 2 are stacked, the nested structure on the frame 22 of one winding assembly cooperates with the corresponding structure on the frame 22 of the other winding assembly to fix the two winding assemblies relatively in the axial direction and prevent them from axially shifting along the central column 11 of the magnetic core.

[0057] The secondary copper sheet 21 is provided with a heat dissipation section 211, which extends beyond the outer edge of the winding conductor 23. In this embodiment, the heat dissipation section 211 is a bent portion of the secondary copper sheet 21, and its extension direction is parallel to the axial direction of the magnetic core column 11. The heat dissipation section 211 is made of copper, which has good thermal conductivity and can directly lead the heat generated inside the winding assembly 2 during operation to the outside of the winding, thereby effectively reducing the temperature rise of the winding.

[0058] During assembly, each winding assembly 2 is first prefabricated, that is, the secondary copper sheet 21 is fixedly connected to the frame 22 to form a winding shaft, and then the winding wire 23 is wound on the winding shaft. Subsequently, the prefabricated winding assemblies 2 are sequentially sleeved onto the magnetic core column 11, and the nesting structure on the frame 22 makes the adjacent winding assemblies 2 stacked and limited in the axial direction. Finally, the first magnetic core and the second magnetic core are fastened together to clamp all the stacked winding assemblies 2, completing the transformer assembly.

[0059] In the above structure, since each winding assembly 2 is an independent prefabricated functional unit, the required number of winding assemblies 2 can be sequentially nested onto the core column 11 to flexibly configure the turns ratio according to different voltage conversion requirements. When the power system is upgraded or changed, there is no need to replace the entire transformer, thereby reducing adaptation costs. During the stacking of winding assemblies 2, adjacent frames 22 directly form axial stacking limits through a nested structure. The relative positions of each winding assembly 2 on the core column 11 can be maintained without additional independent fasteners or a large amount of adhesive. Moreover, the nested structure, as part of the frame 22 itself, does not occupy additional axial space, which helps to achieve transformer miniaturization and improve power density. The heat generated by the winding conductor 23 during operation is conducted through the secondary copper sheet 21 in close contact with it to the heat dissipation part 211 extending beyond the outer edge of the winding conductor 23. The high thermal conductivity of copper is used to directly conduct the heat to the outside of the winding, which can shorten the heat conduction path, effectively reduce the winding temperature rise, and improve heat dissipation efficiency. Each winding assembly has a skeleton that integrates secondary copper sheets and winding wires to form a complete primary and secondary functional unit. During assembly, the prefabricated winding assemblies are simply stacked and nested on the central column of the magnetic core. There is no need for complex winding and insulation treatment during the assembly process, which can improve assembly efficiency and product consistency.

[0060] Based on the above embodiments, the specific structure of the skeleton is further defined. As a preferred embodiment, please refer to [reference needed]. Figure 4 The frame 22 includes a plate 221 and multiple cantilever arms 222. The plate 221 has a ring-shaped structure with a central hole 223 in its middle, through which the magnetic core post 11 passes. The multiple cantilever arms 222 are arranged around the outer edge of the central hole 223 on the plate 221 and extend to one side along the axial direction of the magnetic core post 11. The extended end of each cantilever arm 222 is fixedly connected to the secondary copper sheet 21, thereby connecting the secondary copper sheet 21 and the frame 22 together, which together form a winding shaft.

[0061] In this embodiment, there are eight cantilever arms 222. All cantilever arms 222 are preferably integrally injection molded with the plate 221 to form a stable skeleton structure. The cantilever arms 222 are evenly spaced along the circumference of the plate 221. Gaps are left between adjacent cantilever arms 222. These gaps provide flow space for any subsequent heat transfer medium and also reduce the overall weight of the skeleton 22. The cantilever arms 222 are elastic and made of a material with a certain degree of elasticity, allowing them to deform appropriately when connected to the secondary copper sheet 21, facilitating installation and ensuring a secure connection.

[0062] Based on the above embodiments, the fixed connection method between the cantilever 222 and the secondary copper sheet 21 is further defined. As a preferred embodiment, the cantilever 222 is provided with a snap-fit ​​structure for forming a snap-fit ​​engagement with the secondary copper sheet 21.

[0063] In this embodiment, the secondary copper sheet 21 has a copper sheet center hole 212 through which the magnetic core column 11 passes. The copper sheet center hole 212 is coaxially arranged with the skeleton center hole 223 on the skeleton 22. Furthermore, the extended ends of multiple cantilever 222 can also pass through the copper sheet center hole 212 respectively, and are fixed to the secondary copper sheet 21 by a snap-fit ​​structure on the cantilever 222. With this structure, the connection between the skeleton 22 and the secondary copper sheet 21 no longer relies on additional fasteners or adhesives, but is achieved through the direct snap-fit ​​between the cantilever 222 and the secondary copper sheet 21, facilitating assembly and effectively simplifying the assembly process of the winding assembly 2.

[0064] Based on the above embodiments, the engagement structure between the cantilever 222 and the secondary copper sheet 21 is further defined. As a preferred embodiment, please refer to... Figure 4 and Figure 5 A portion of the cantilever 222 has an anti-retraction stop 224 on its outer peripheral wall. When the cantilever 222 passes through the center hole 212 of the secondary copper sheet 21, the anti-retraction stop 224 abuts against one side of the secondary copper sheet 21 (i.e., the side facing away from the installation direction) to prevent the secondary copper sheet 21 from detaching from the frame 22. Specifically, the anti-retraction stop 224 is a protruding block on the outer peripheral wall of the cantilever 222, which has a vertical abutment surface facing the secondary copper sheet 21. When the secondary copper sheet 21 is installed in place, the abutment surface forms a surface contact with the side of the secondary copper sheet 21, thereby preventing the secondary copper sheet 21 from retracting axially.

[0065] Please refer to Figure 4 and Figure 6Another portion of the cantilever 222 has an extension stop 225 on its outer peripheral wall. The extension stop 225 is located on the cantilever 222 closer to the plate 221 than the anti-retraction stop 224. It abuts against the other side of the secondary copper plate 21 (i.e., the side facing the installation direction), limiting the extension position of the secondary copper plate 21 along the installation direction. The extension stop 225 is also a protruding block on the outer peripheral wall of the cantilever 222. When the secondary copper plate 21 is pushed in axially, its front end abuts against the extension stop 225. At this point, the operator can sense that the secondary copper plate 21 has been installed to the predetermined position and cannot be pushed further.

[0066] In this embodiment, the anti-retraction stop 224 and the extension stop 225 are staggered on multiple cantilever 222. For example, an anti-retraction stop 224 is set every other cantilever, and the extension stop 225 is set on the remaining cantilever. This can make the secondary copper sheet 21 be subjected to uniform force in the circumferential direction, and avoid tilting or jamming due to force on one side.

[0067] Through the cooperation of the anti-retraction stop 224 and the extension stop 225, the frame 22 and the secondary copper sheet 21 are reliably fixed without additional fasteners or adhesives. The anti-retraction stop 224 effectively prevents the secondary copper sheet 21 from loosening from the frame 22 due to vibration or thermal expansion and contraction during use, while the extension stop 225 ensures that the secondary copper sheet 21 in each winding assembly 2 is accurately installed in the predetermined position on the frame. This bidirectional limiting structure simplifies the assembly process; the operator only needs to push the secondary copper sheet 21 into the extension stop 225 to complete the installation without additional positioning or fastening operations, thereby improving assembly efficiency and product consistency. At the same time, since the locking structure (i.e., the anti-retraction stop 224 and the extension stop 225) is directly integrated into the cantilever 222, it can be manufactured as a single piece without adding extra parts, which is beneficial for cost control and miniaturization design.

[0068] Based on the above embodiments, the connection method between the cantilever 222 and the secondary copper sheet 21 is further defined. As a preferred embodiment, please refer to... Figure 4 , Figure 5 and Figure 7 At least one cantilever 222 is provided with an anti-rotation part 226, and the secondary copper sheet 21 is provided with a notch 213 that matches the anti-rotation part 226. The anti-rotation part 226 and the notch 213 engage and limit the movement to prevent the secondary copper sheet 21 from rotating relative to the frame 22.

[0069] In this embodiment, an anti-rotation portion 226 is provided on the outer peripheral wall of a cantilever, and is positioned before the extension stop 225 along the installation direction (i.e., the direction in which the secondary copper plate 21 is pushed in). The anti-rotation portion 226 is a positioning protrusion protruding from the outer peripheral wall of the cantilever 222. Its shape is rectangular or trapezoidal, and it has a certain length along the axial direction perpendicular to the central hole 223 of the frame, so as to form a stable engagement with the notch 213 on the secondary copper plate 21.

[0070] Correspondingly, the secondary copper sheet 21 has notches 213 that match the anti-rotation portion 226, arranged radially outward from the center hole 212. The number and position of the notches 213 correspond one-to-one with the anti-rotation portions 226. When the secondary copper sheet 21 is pushed in along the installation direction, the notches 213 must be aligned with the anti-rotation portions 226 before it can be pushed in further; if the notches 213 are not aligned with the anti-rotation portions 226, the anti-rotation portions 226 will interfere with the inner edge of the secondary copper sheet 21, preventing the secondary copper sheet 21 from being pushed in further. When the secondary copper sheet 21 is pushed in to the extension stop 225, the anti-rotation portions 226 are completely embedded in the notches 213, and the two form a locking and limiting action. At this point, the sidewall of the anti-rotation part 226 abuts against the sidewall of the notch 213, effectively preventing the secondary copper sheet 21 from rotating circumferentially relative to the frame 22 due to vibration or external force during use. This ensures that the position of the secondary copper sheet 21 remains fixed when the winding conductor 23 is wound on the winding shaft, preventing the winding conductor 23 from being subjected to torsional stress or displacement due to the rotation of the copper sheet, which would affect the electrical performance and reliability of the winding. In addition, the anti-rotation part 226 also plays a guiding and error-prevention role during installation. The operator must align the notch 213 of the secondary copper sheet 21 with the anti-rotation part 226 for successful installation, avoiding reverse installation or incorrect placement, further improving the accuracy and efficiency of assembly.

[0071] Preferably, the notch 213 is located at the end of the secondary copper sheet 21 away from its heat dissipation part 211. When installing the secondary copper sheet 21, the operator first aligns the center hole 212 of the copper sheet with the extension end of the cantilever 222 and pushes it in. Since the heat dissipation part 211 is usually located at the outer end of the secondary copper sheet 21 and has a certain bent shape, if the notch 213 is located at the end close to the heat dissipation part 211, the heat dissipation part 211 needs to be oriented in a specific direction during installation, limiting the operating space and making observation and adjustment inconvenient. By setting the notch 213 at the end away from the heat dissipation part 211, i.e., the end close to the frame 22 plate 221, the notch 213 is located at the front end of the installation pushing direction. When the operator pushes in the secondary copper sheet 21, the notch 213 can first contact the anti-rotation part 226 on the cantilever 222, facilitating alignment at the initial stage of installation without the need for angle adjustment, thus improving assembly efficiency.

[0072] Based on the above embodiments, the nesting structure of the skeleton 22 is further defined. As a preferred embodiment, please refer to... Figure 8 Each cantilever 222 has a protrusion 227 at its distal end, and the inner edge of the central hole 223 of the frame has multiple notches 228 that correspond to and match the multiple protrusions 227. The protrusions 227 and the notches 228 are adapted in shape and size to form a fitting fit.

[0073] When two winding assemblies 2 are stacked, the protrusion 227 on the skeleton 22 of one winding assembly 2 is inserted into the notch 228 on the skeleton 22 of the adjacent winding assembly 2, forming a fitting connection. Specifically, the distal end of the cantilever 222 of the front winding assembly 2 passes through the central hole 223 of the skeleton of the rear winding assembly 2, and its protrusion 227 engages with the notch 228 of the rear skeleton 22, thereby fixing the two adjacent winding assemblies 2 relative to each other in the axial direction.

[0074] The aforementioned nested structure eliminates the need for separate fasteners or excessive adhesives between adjacent winding assemblies 2. Axial stacking and positioning are achieved solely through the engagement of the protrusion 227 and the notch 228, preventing axial displacement of the winding assemblies 2 along the core column 11. The engagement structure of the protrusion 227 and the notch 228 is integrated into the frame 22 itself, allowing for integral fabrication without additional axial space requirements, thus facilitating transformer miniaturization. Furthermore, the engagement structure provides a positioning indicator during assembly. When the protrusion 227 is fully engaged with the notch 228, the operator experiences a slight locking sensation, indicating that the adjacent winding assemblies 2 have been installed in their intended relative positions, facilitating quick and accurate stacking assembly. In addition, the engagement of the protrusion 227 and the notch 228 also limits the relative rotation of adjacent winding assemblies 2 to a certain extent, working in conjunction with the aforementioned anti-rotation part 226 to further enhance the circumferential stability of each winding assembly 2 after stacking.

[0075] Based on the above embodiments, to further improve the heat dissipation performance of the winding, as a preferred option, please refer to... Figure 9 and Figure 10 The frame 22 is provided with a heat-conducting hollow structure, specifically including a first heat-conducting hollow 229 and a second heat-conducting hollow 2210.

[0076] The first heat-conducting perforation 229 is formed by the gap between two adjacent cantilevers 222. Since multiple cantilevers 222 are distributed circumferentially along the plate 221, axially extending perforation gaps are naturally formed between adjacent cantilevers 222. When the winding assembly 2 is fitted onto the core post 11, these perforation gaps are located on the heat conduction path between the core post 11 and the winding conductor 23. The heat generated by the winding conductor 23 during operation can be dissipated through air convection in the perforation gaps, shortening the heat conduction path and effectively reducing the winding temperature rise.

[0077] The second heat-conducting perforation 2210 is provided on the plate 221 of the skeleton 22. Specifically, the plate 221 has multiple through perforations, which are located on the heat conduction path between the secondary copper sheet 21 and the winding wire 23. When the winding wire 23 is wound on the winding shaft, it contacts the plate 221. The second heat-conducting perforation 2210 on the plate 221 allows heat to be directly dissipated from a portion of the winding wire 23, reducing the thickness of the skeleton material through which heat needs to pass.

[0078] In this embodiment, the first thermally conductive perforation 229 and the second thermally conductive perforation 2210 can be provided simultaneously, or only one of them can be provided according to actual needs. The two perforation structures work together to construct multi-directional heat conduction channels on the frame 22, thereby effectively reducing the internal thermal resistance of the winding assembly 2 and improving the overall heat dissipation efficiency. At the same time, the perforation structure is part of the frame 22 itself, without adding extra parts or occupying axial space, which is conducive to maintaining the miniaturized design of the transformer.

[0079] Based on the above embodiments, the second heat-conducting perforation 2210 is further optimized; please refer to [reference needed]. Figure 11 The plate 221 of the skeleton 22 is provided with a guide groove 2211, which is connected to the second heat-conducting hollow 2210.

[0080] Specifically, the guide groove 2211 is a groove structure formed by a recess on the surface of the plate 221, one end of which connects to the second heat-conducting perforation 2210, and the other end extends to the edge or outer surface of the skeleton 22. The cross-sectional shape of the guide groove 2211 can be rectangular or trapezoidal, and its size is sufficient to allow the heat-conducting adhesive to flow smoothly. Multiple guide grooves 2211 can be respectively provided corresponding to multiple second heat-conducting perforations 2210.

[0081] After the transformer is assembled, thermally conductive adhesive can be injected into the guide groove 2211. The adhesive flows along the guide groove 2211 and eventually flows into the second thermally conductive perforation 2210, filling the gaps in the perforated area. After the adhesive cures, a solid thermally conductive connection is formed between the secondary copper sheet 21 and the winding conductor 23, further enhancing the connection strength between the secondary copper sheet 21 and the frame 22, and improving the overall structural stability of the winding assembly 2. Meanwhile, the guide groove 2211 is integrally formed as part of the frame 22, requiring no additional parts and occupying no extra space, thus maintaining the miniaturized design of the transformer while achieving the above functions.

[0082] Based on the above embodiments, the auxiliary functions of the skeleton 22 are further defined. Please refer to [reference needed]. Figure 12 The frame 22 is provided with a wire management structure 2212 for fixing the lead wires 231 of the winding conductors 23.

[0083] In this embodiment, the wire management structure 2212 is located at the edge of the plate 221 of the skeleton 22. The wire management structure 2212 is specifically a hook-shaped structure that protrudes outward from the surface of the skeleton 22 and forms a groove. After the winding conductor 23 is wound, its lead wire 231 can be embedded in the groove of the hook-shaped structure. The limiting effect of the hook-shaped structure prevents the lead wire 231 from becoming loose or shifting. The number and position of the wire management structures 2212 are determined according to the number and direction of the lead wire 231.

[0084] More preferably, such as Figure 15 As shown, the wire management structure 2212 is located at the end of the frame 22 facing away from the heat dissipation part, while the wire management frame 5 is located adjacent to the magnetic core 1 at the end facing away from the heat dissipation part 211. In this way, after assembly, the end of the transformer where the heat dissipation part 211 is located primarily conducts heat, while the other end where the wire management structure 2212 is located is used for organizing and fixing the lead wires; the two do not interfere with each other. After the lead wires 231 of the winding conductors 23 are initially fixed by the wire management structure 2212, they can be further gathered on the wire management frame 5 for unified organization and positioning. This layout creates a neat routing path for the lead wires at one end of the transformer, facilitating subsequent connection with external components and improving assembly efficiency and reliability. Simultaneously, concentrating the lead wires at the end facing away from the heat dissipation part prevents them from obstructing the heat dissipation part 211 or affecting the heat dissipation airflow channel, ensuring that the heat dissipation function is not affected.

[0085] Based on the above embodiments, the stacking layout of the winding assembly 2 is further defined. As a preferred embodiment, please refer to [reference needed]. Figure 3 When two adjacent winding assemblies 2 are stacked, the skeleton 22 of one winding assembly 2 is arranged adjacent to the secondary copper sheet 21 of the other winding assembly 2.

[0086] Taking two adjacent winding assemblies 2 as an example, in the winding assembly 2 on the left, the side of its skeleton 22 facing right is adjacent to the side of the secondary copper sheet 21 facing left in the winding assembly 2 on the right. After stacking multiple winding assemblies 2 in this manner, there is a skeleton 22 between any two adjacent secondary copper sheets 21. That is, in the stacking direction, the secondary copper sheets 21 and skeletons 22 are arranged alternately. This alternating arrangement is achieved by controlling the installation orientation of each winding assembly 2. During the prefabrication of each winding assembly 2, the relative positions of the secondary copper sheet 21 and skeleton 22 are fixed. During installation, by selecting the orientation of the winding assembly 2, the skeleton 22 of one of the two adjacent winding assemblies 2 is adjacent to the secondary copper sheet 21 of the other.

[0087] Thus, any two adjacent secondary copper sheets 21 are separated by a frame 22. Since the frame 22 is made of insulating material, such as a plastic frame, it itself provides electrical isolation. Therefore, no additional insulating layer or material is needed between adjacent secondary copper sheets 21 to achieve electrical isolation. This saves on insulating material costs and avoids additional insulating layers occupying axial space, which is beneficial for miniaturizing the transformer design. At the same time, as a necessary component of each winding assembly 2, the isolation function of the frame 22 is inherent to the structure itself, without adding any extra parts or assembly steps, simplifying the manufacturing process.

[0088] Based on the above embodiments, the stacking layout of the winding assembly 2 is further defined. As a preferred embodiment, please refer to... Figure 3 and Figure 14 In this embodiment, at least one additional secondary copper sheet 3 is also included. The additional secondary copper sheet 3 is sleeved on the magnetic core column 11 together with the winding assembly 2, and the additional secondary copper sheet 3 is disposed between two adjacent winding assemblies 2, with its two sides respectively adjacent to the skeleton 22 of the two adjacent winding assemblies 2.

[0089] A specific arrangement, such as Figure 3 As shown, this embodiment includes three winding assemblies 2 and one additional secondary copper sheet 3, arranged sequentially along the axial direction of the magnetic core central column 11 as follows: first magnetic core 1, first winding assembly 2, second winding assembly 2, additional secondary copper sheet 3, third winding assembly 2, and second magnetic core 1. Specifically, the secondary copper sheet 21 of the first winding assembly 2 faces to the left (adjacent to the first magnetic core 1), and its frame 22 faces to the right; the secondary copper sheet 21 of the second winding assembly 2 also faces to the left, and its frame 22 faces to the right; the additional secondary copper sheet 3 is located between the frame 22 of the second winding assembly 2 and the frame 22 of the third winding assembly 2; the frame 22 of the third winding assembly 2 faces to the left, and its secondary copper sheet 21 faces to the right (adjacent to the second magnetic core 1).

[0090] According to this layout, the two sides of the additional secondary copper sheet 3 are respectively adjacent to the skeleton 22 of the second winding assembly 2 and the skeleton 22 of the third winding assembly 2. Since the skeleton 22 is made of insulating material, the additional secondary copper sheet 3 is separated from the secondary copper sheets 21 in the two winding assemblies 2 by the skeleton 22, thus maintaining electrical isolation.

[0091] The structure of the additional secondary copper sheet 3 is the same as that of the secondary copper sheet 21 in the winding assembly 2. It also has a heat dissipation part and a central hole for the magnetic core column 11 to pass through, so as to be fitted onto the magnetic core column 11. Its heat dissipation part is oriented in the same direction as the heat dissipation part 211 of each winding assembly 2, which facilitates centralized heat dissipation.

[0092] Without increasing the number of winding assemblies 2, depending on the actual application requirements, the additional secondary copper sheet 3 can be connected to the secondary circuit. It can serve as part of the secondary winding, increasing current carrying capacity; or it can be grounded, acting as an electrostatic shielding layer to suppress common-mode interference between the primary and secondary windings, improving electromagnetic compatibility; or it can simply serve as an auxiliary heat dissipation structure, participating in the heat dissipation within the winding assembly 2. This provides the transformer with flexible functional expansion space, further enhancing its adaptability. Furthermore, the additional secondary copper sheet 3 is located between the frames 22 of two adjacent winding assemblies 2, fully utilizing the insulating isolation function of the frames 22 to maintain electrical isolation from the secondary copper sheets 21 in the two winding assemblies 2, eliminating the need for additional insulating layers, thus simplifying the structure and saving axial space. Simultaneously, the additional secondary copper sheet 3 itself also has a heat dissipation section, participating in the heat dissipation within the winding assembly 2, further improving the overall heat dissipation effect.

[0093] Based on the above embodiments, the magnetic core structure is further defined as a preferred embodiment. Please refer to [reference needed]. Figures 13 to 14 The magnetic core 1 includes a first magnetic core and a second magnetic core that interlock with each other, together forming a clamping space to accommodate all the stacked winding assemblies 2 and the additional secondary copper sheets 3. Adhesive can be applied to the joint surface of the first and second magnetic cores to enhance fixation and prevent the magnetic cores from loosening.

[0094] In this embodiment, as Figure 1 As shown, each secondary copper sheet 21 and additional secondary copper sheet 3 in each winding assembly 2 are provided with heat dissipation parts 211, and these heat dissipation parts 211 extend out of the clamping space in the same direction. Specifically, the heat dissipation parts 211 extend from the first end of the magnetic core 1 and are exposed to the external environment so as to directly dissipate the heat generated inside the winding assembly 2 during operation to the surrounding air.

[0095] like Figure 2 As shown, an insulating plate 4 is provided at the other end of the magnetic core 1 away from the heat dissipation part 211 (i.e., the second end of the magnetic core 1). The insulating plate 4 can be made of insulating material, and its shape is adapted to the end contour of the magnetic core 1. The insulating plate 4 has a plurality of through holes 41, the position, number and size of which correspond one-to-one with the ends of each secondary copper sheet 21 and the additional secondary copper sheet 3 away from the heat dissipation part 211. After assembly, the lead-out ends (i.e., the ends away from the heat dissipation part 211) of each secondary copper sheet 21 and the additional secondary copper sheet 3 pass through the corresponding through holes 41 and extend to the outside of the clamping space.

[0096] In this embodiment, the perforations 41 on the insulating plate 4 are arranged side by side, matching the positions of each secondary copper sheet 21 and the additional secondary copper sheet 3. The size of the perforations 41 is slightly larger than the cross-sectional size of the copper sheet to facilitate assembly.

[0097] In the aforementioned structure, the clamping space formed by the interlocking magnetic cores 1 tightly houses all the winding assemblies 2 and the additional secondary copper sheets 3, ensuring the axial relative positions of each component are fixed and making the entire transformer structure compact and aesthetically pleasing. The design of the heat dissipation section 211 extending out of the clamping space allows heat from the windings to be directly dissipated to the external environment, preventing heat accumulation inside the magnetic core and effectively reducing the transformer's operating temperature rise. The layout of the copper sheets concentrating through the insulating plate 4 facilitates subsequent connection to external devices. Specifically, the transformer achieves functional partitioning perpendicular to its axial direction. The heat dissipation sections 211 of each copper sheet extend towards the first end of the magnetic core 1, facilitating concentrated heat dissipation. The lead-out ends of each copper sheet extend towards the second end of the magnetic core 2 and are uniformly aligned through the perforations 41 on the insulating plate 4. This layout separates the heat dissipation and electrical connection functional areas, preventing mutual interference.

[0098] In addition, the insulating plate 4 positions and fixes each copper sheet, preventing them from shifting or coming into contact with each other during assembly or use, thus ensuring the reliability of the electrical connection. At the same time, as an insulating material, the insulating plate 4 enhances the electrical isolation between the end of the magnetic core 1 and the external circuit, improving the safety of the transformer.

[0099] Based on the above embodiments, the arrangement of the heat dissipation part 211 is limited. As a preferred embodiment, the portions of the secondary copper sheet 21 and the additional secondary copper sheet 3 that extend out of the clamping space are bent to form the heat dissipation part 211. The heat dissipation part 211 extends along the axial direction parallel to the central column 11 of the magnetic core and is placed on the first end of the magnetic core 1. The distance between the heat dissipation part 211 and the first end of the magnetic core 1 in the vertical direction is consistent.

[0100] In this embodiment, the first end of the magnetic core 1 is an end face of the transformer perpendicular to its axial direction. Each heat dissipation part 211 extends towards this end face and out of the clamping space, and all heat dissipation parts 211 extend to the same height. Therefore, multiple heat dissipation surfaces with multiple heat dissipation parts 211 arranged in a flush manner are formed at one end of the transformer, realizing concentrated heat dissipation and improving heat dissipation efficiency and uniformity. At the same time, the consistent height of each heat dissipation part 211 can avoid assembly interference caused by differences in the height of each heat dissipation part, ensuring a more regular overall structure and appearance of the transformer.

[0101] It should be noted that the extension length of each heat dissipation part 211 generally does not exceed the thickness of the winding wire 23, so as to avoid the heat dissipation part 211 being too long and causing its end to interfere with the magnetic core 1 or another heat dissipation part 211 adjacent to it.

[0102] More preferably, the width of the secondary copper sheet 21 and the additional secondary copper sheet 3 is close to the winding width of the winding wire 23, which is used to increase the contact area between the copper sheet and the winding wire. On the one hand, it can reduce the resistance between the two and improve the power transmission efficiency. On the other hand, it can make the heat generated inside the winding more quickly transferred to the copper sheet and then discharged through the heat dissipation part, effectively reducing the temperature rise of the winding.

[0103] It should be noted that in this specification, relational terms such as first and second are used only to distinguish one entity from several other entities, and do not necessarily require or imply any such actual relationship or order between these entities.

[0104] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0105] The modular winding stacked transformer provided by this invention has been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the embodiments above are merely for the purpose of helping to understand the method and core ideas of this invention. It should be noted that those skilled in the art can make various improvements and modifications to this invention without departing from its principles, and these improvements and modifications also fall within the protection scope of the claims of this invention.

Claims

1. A modular winding stacked transformer, characterized in that, include: The magnetic core (1) is provided with a core column (11); At least two winding assemblies (2) are stacked along the axial direction of the magnetic core column (11), and each winding assembly (2) is sleeved on the magnetic core column (11). Each of the winding assemblies (2) includes a secondary copper sheet (21), a frame (22), and a winding conductor (23). The secondary copper sheet (21) is fixedly connected to the frame (22) and forms a winding shaft. The winding conductor (23) is wound around the winding shaft. The frame (22) has a nested structure for axial stacking and limiting with the frame (22) of another adjacent winding assembly (2). The secondary copper sheet (21) has a heat dissipation part (211) extending beyond the outer edge of the winding conductor (23) to increase the heat dissipation effect.

2. The modular winding stacked transformer according to claim 1, characterized in that, The skeleton (22) includes a plate (221) and a plurality of cantilever arms (222). The plate (221) has a skeleton center hole (223) through which the magnetic core column (11) passes. The plurality of cantilever arms (222) are disposed on the plate (221) around the outer edge of the skeleton center hole (223) and extend along the axial direction of the magnetic core column (11) and are fixedly connected to the corresponding secondary copper sheet (21) to form the winding shaft.

3. The modular winding stacked transformer according to claim 2, characterized in that, One portion of the cantilever (222) has an anti-retraction stop (224) on its outer peripheral wall, which passes through the copper plate center hole (212) of the secondary copper plate (21) and abuts against one side of the secondary copper plate (21) to prevent the secondary copper plate (21) from detaching from the frame (22); another portion of the cantilever (222) has an extension stop (225) on its outer peripheral wall, which abuts against the other side of the secondary copper plate (21) to limit the extension position of the secondary copper plate (21) along the installation direction.

4. The modular winding stacked transformer according to claim 2, characterized in that, At least one of the cantilever (222) is provided with an anti-rotation part (226), and the secondary copper plate (21) is provided with a notch (213) that matches the anti-rotation part (226). The anti-rotation part (226) and the notch (213) engage and limit each other to prevent the secondary copper plate (21) from rotating relative to the frame (22).

5. The modular winding stacked transformer according to claim 2, characterized in that, The nested structure includes a protrusion (227) and a notch (228). The distal end of each cantilever (222) is provided with the protrusion (227). The inner edge of the central hole (223) of the skeleton is provided with a plurality of notches (228) that correspond to and match the plurality of protrusions (227). In two adjacent winding assemblies (2), the protrusion (227) of the skeleton (22) of one winding assembly (2) is fitted into the notch (228) of the skeleton (22) of the other winding assembly (2) to form an axial stacking limit.

6. The modular winding stacked transformer according to claim 2, characterized in that, A gap is left between two adjacent cantilever (222) to form a first heat-conducting perforation (229) on the heat-conducting path between the magnetic core column (11) and the winding wire (23); and / or, the plate (221) of the skeleton (22) is provided with a second heat-conducting perforation (2210) on the heat-conducting path between the secondary copper sheet (21) and the winding wire (23).

7. The modular winding stacked transformer according to claim 6, characterized in that, The frame (22) plate (221) is provided with a guide groove (2211) that connects to the second heat-conducting hollow (2210) for allowing heat-conducting adhesive to flow into the second heat-conducting hollow (2210).

8. The modular winding stacked transformer according to claim 1, characterized in that, In two adjacent winding assemblies (2), the skeleton (22) of one winding assembly (2) is arranged adjacent to the secondary copper sheet (21) of the other winding assembly (2), such that the skeleton (22) is spaced between any two adjacent secondary copper sheets (21).

9. The modular winding stacked transformer according to claim 1, characterized in that, It also includes at least one additional secondary copper sheet (3), which is sleeved together with the winding assembly (2) on the magnetic core central column (11), and the additional secondary copper sheet (3) is disposed between two adjacent winding assemblies (2), and the two sides of the additional secondary copper sheet (3) are respectively disposed adjacent to the skeleton (22) of the two adjacent winding assemblies (2).

10. The modular winding stacked transformer according to any one of claims 1 to 9, characterized in that, The magnetic core (1) includes a first magnetic core (1) and a second magnetic core (1) that are fastened together to form a clamping space. The heat dissipation portions (211) of the secondary copper sheet (21) and the additional secondary copper sheet (3) extend out of the clamping space. The magnetic core (1) has an insulating plate (4) at one end away from the heat dissipation portion (211). The insulating plate (4) has through holes (41) for the secondary copper sheet (21) and the additional secondary copper sheet (3) to pass through.

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