High-voltage transformer and inductor integrated structure for vehicle-mounted charger of electric vehicle

Abstract

The utility model discloses a high-voltage transformer and inductor integrated structure for a vehicle-mounted charger of an electric vehicle. The inductor and the high-voltage transformer are connected in series through a primary coil wound by a whole copper wire, a mounting groove matched with the high-voltage transformer in shape is formed in the upper end face of the shell, and an integrated structure of the inductor and the high-voltage transformer is arranged in the shell through the mounting groove; the cooling fins are arranged on the peripheries of the surfaces of the transformer magnetic core and the inductor magnetic core; buckles are arranged on the transformer framework; a clamping ring is arranged at the position, corresponding to the buckle, of the edge of the installation groove, the starting ends and the tail ends of the primary coil and the secondary coil penetrate through the corresponding wire clamping grooves to be fixed, the tail end of the primary coil wound on the inductor framework and the transformer framework penetrates through the corresponding position of the wire passing groove, and the buckle is matched with the clamping ring. By using the high-voltage transformer and inductor integrated structure of the vehicle-mounted charger of the electric vehicle, the heat dissipation efficiency can be ensured while the size is controlled to be small; and the use reliability is ensured while the production efficiency is improved.

Description

Technical Field

[0001] The utility model relates to the technical field of on-board chargers for electric vehicles, and in particular to a high-voltage transformer and an inductor integrated structure for on-board chargers for electric vehicles. Background Art

[0002] In order to reduce the heat generated by electric vehicles during charging, improve charging efficiency, and reduce manufacturing costs, high-voltage fast charging technology is now widely used. As the power of on-board chargers increases, the voltage increases, the size decreases, and the demand for electric vehicles increases, higher requirements for heat dissipation, volume, insulation, and cost are also put forward for the high-voltage transformers and inductors.

[0003] The high-voltage transformer and inductor of the on-board charger are generally soldered to the circuit board by pin soldering. The disadvantages of this are: it takes a lot of work hours to calibrate the pins; soldering is not suitable for heavy high-voltage transformers and inductors. The vibration environment during car driving can easily cause the solder joints of heavy high-voltage transformers and inductors to fall off and fail; welding on the circuit board is not conducive to separate potting insulation and cooling; the coil tail production process requires the use of tape to fix the wire tail, otherwise the coil will become scattered during production and transportation, which will cause changes in electrical performance; the maintainability is poor after soldering, and there may be defects such as cold soldering, oxidation, and pad detachment after manual repair. Utility Model Content

[0004] In view of the higher requirements for the high-voltage transformer and inductor of the on-board charger of an electric vehicle, the utility model provides a high-voltage transformer and inductor integrated structure for the on-board charger of an electric vehicle. The high-voltage transformer is directly installed in the on-board charger of the electric vehicle through the fixing holes on the shell. Since the installation points on the shell are more consistent, it is easier to realize automated production.

[0005] The technical scheme of the utility model is: a high-voltage transformer and inductor integrated structure for an on-board charger of an electric vehicle, comprising an inductor and a high-voltage transformer, wherein the inductor and the high-voltage transformer are connected in series by a primary coil wound by a whole copper wire, and further comprising a shell and a heat sink, wherein a mounting groove matching the shape of the high-voltage transformer is arranged on the upper end surface of the shell, and the integrated structure of the inductor and the high-voltage transformer is arranged in the shell through the mounting groove; the heat sink is arranged around the surface of the transformer core and the inductor core; two connecting terminals I of the primary coil and two connecting terminals II of the secondary coil are respectively connected to the terminal mounting holes on the terminal connection seat; a wire clamping groove is arranged at the upper end of one side of the transformer skeleton, and a wire passing groove is arranged at the upper end of the other side of the transformer skeleton; a buckle is arranged on the transformer skeleton; a clamping ring is arranged at the corresponding position of the edge of the mounting groove and the buckle, the starting end and the tail end of the primary coil and the secondary coil are respectively fixed through the corresponding wire clamping groove, the tail end of the primary coil wound on the inductor skeleton and the transformer skeleton passes through the corresponding position of the wire passing groove, and the buckle and the clamping ring cooperate.

[0006] In the above technical solution, the support plate of the terminal connection seat is a hollow plate, the position of the terminal mounting hole on the terminal connection seat corresponds to the position of the connection terminal of the vehicle charger; and a baffle is arranged between every two adjacent terminal mounting holes.

[0007] In the above technical solution, both the connection terminal I and the connection terminal II are L-shaped, and inverted teeth are respectively provided on both sides of the insertion ends of the connection terminal I and the connection terminal II.

[0008] Furthermore, there are four buckles, namely longitudinal buckle I, transverse buckle II, transverse buckle III and transverse buckle IV, which are respectively arranged at the four corners of the transformer skeleton, and the direction of the longitudinal buckle I is parallel to the axial direction of the transformer skeleton, and the directions of the transverse buckle II, transverse buckle III and transverse buckle IV are perpendicular to the longitudinal buckle I; correspondingly, there are four snap rings, namely longitudinal snap ring I, transverse snap ring II, transverse snap ring III and transverse snap ring IV, which are respectively arranged at the four corners of the mounting groove, and the direction of the longitudinal snap ring I is perpendicular to the transverse snap ring II, transverse snap ring III and transverse snap ring IV; the longitudinal snap ring I, transverse snap ring II, transverse snap ring III and transverse snap ring IV correspond one-to-one to the positions of the longitudinal snap ring I, transverse snap ring II, transverse snap ring III and transverse snap ring IV respectively.

[0009] Furthermore, the transformer skeleton, transformer air gap sheet, inductor skeleton and inductor air gap sheet are made of plastic with a thermal conductivity ≥2.5W / mK; the adhesive between the transformer magnetic sheet and the transformer air gap sheet, and between the inductor magnetic sheet and the inductor air gap sheet is made of a soft material adhesive with a thermal conductivity ≥1.0W / mK; the adhesive between the inductor core surface and the transformer core surface and the heat sink is made of a thermal conductive adhesive with a thermal conductivity ≥1.0W / mK.

[0010] The beneficial effects of the utility model are:

[0011] The integrated body of the transformer and the inductor is assembled in the casing, and the high-voltage transformer is directly installed in the on-board charger of the electric vehicle through the mounting holes on the casing. Since the mounting holes on the casing are more consistent, it is easier to realize automated production, the installation operation is more convenient, the installation position is more accurate, and the casing has a certain sealing effect, which is convenient for the separate potting operation of the high-voltage transformer and the inductor. The use of screws to fix it can be repeatedly disassembled, which provides higher maintainability than pin soldering fixation.

[0012] The wire slot structure fixes the coil tail, reducing the material and labor costs of tape pasting, and more effectively preventing defects caused by coil loosening. At the same time, the wire position will not change in a vibrating environment, effectively ensuring the safety distance between the input and output wires;

[0013] Use high thermal conductivity plastic and stick a heat sink on the surface of the core, which can contact with epoxy resin after potting to provide higher heat dissipation efficiency;

[0014] The terminal connector fixes the relative positions of the four terminal mounting holes, and can align the four terminal fixing holes at one time when installing the electric vehicle on-board charger. Compared with the pin design, the pin alignment step is removed, which greatly improves the installation operation efficiency and reduces the probability of the coil tail end falling out of the wire slot and causing the wire to be scattered during production and transportation. If screws are used for fixing, it can be disassembled repeatedly, which provides higher maintainability than pin soldering fixation;

[0015] The transformer and the housing are fixed by a single-sided snap fit, which provides a secure fit and a simpler assembly process. The design of three horizontal snaps and one vertical snap makes the housing easy to install and remove and securely fixed. Compared with the method of directly fixing the transformer housing or the inductor housing with glue, this snap fixation provides more assembly margin (the glue is almost completely fixed, and the snap can have a swing margin) and maintenance convenience; compared with the housing that needs to be installed separately on the vehicle charger transformer or inductor, this utility model directly integrates the inductor and the housing on the high-voltage transformer, which has a higher degree of integration and a smaller size, and is more convenient for automated mass production. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic diagram of the structure of the utility model;

[0017] Figure 2 yes Figure 1 Exploded diagram of

[0018] Figure 3 It is a structural schematic diagram of the terminal connection seat of the utility model;

[0019] Figure 4 This is a schematic diagram of the assembly of the connection terminal and the terminal connection seat of the utility model;

[0020] Figure 5 It is a structural schematic diagram of the housing of the utility model;

[0021] Figure 6 This is a schematic diagram of the transformer skeleton structure of the utility model;

[0022] Figure 7 This is a schematic diagram of the inductor skeleton structure of the utility model;

[0023] Figure 8 It is a schematic diagram of the structure of the magnetic core of a utility model transformer;

[0024] Fig. 9 This is a schematic diagram of the structure of the inductor core of the utility model;

[0025] Fig.10 This is the assembly diagram of the inductor frame, transformer frame and coil.

[0026] Fig.11 This is the assembly diagram of the inductor frame, transformer frame, coil, inductor core and transformer core.

[0027] Description of reference numerals: 1, inductor; 1-1, inductor core; 1-1-1, inductor core center column II; 1-1-2, inductor core end surface; 1-2, inductor skeleton; 1-2-1, transformer core matching hole; 1-3, inductor magnetic sheet; 1-4, inductor air gap sheet;

[0028] High-voltage transformer; 2-1, transformer core; 2-1-1, transformer core center column I; 2-1-2, transformer core end surface; 2-1-3, transformer core bottom surface; 2-2, transformer skeleton; 2-3, transformer magnetic sheet; 2-4, transformer air gap sheet; 2-2-1, transformer core matching hole

[0029] 3. Shell; 4. Heat sink;

[0030] 5. Terminal connection seat; 5-1. Terminal mounting hole; 5-2. Baffle; 5-3. Support plate;

[0031] 6-1, connection terminal Ⅰ; 6-1-1, connection hole Ⅰ; 6-1-2, wire hole Ⅰ; 6-2, connection terminal Ⅱ; 6-2-1, connection hole Ⅱ; 6-2-2, wire hole Ⅱ;

[0032] 7. Wire slot; 8. Wire clamp slot; 9. Heat shrink tubing; 10. Secondary coil; 11. Secondary coil; 12. Mounting slot; 13-1. Longitudinal clamp ring I; 13-2 Transverse clamp ring II; 13-3. Transverse clamp ring III; 13-4. Transverse clamp ring IV;

[0033] 14. Mounting hole;

[0034] 15-1, longitudinal buckle Ⅰ; 15-2, transverse buckle Ⅱ; 15-3, transverse buckle Ⅲ; 15-4, transverse buckle Ⅳ DETAILED DESCRIPTION

[0035] The following will be combined with the drawings in the embodiments of the utility model to clearly and completely describe the technical solutions in the embodiments of the utility model. Obviously, the described embodiments are part of the embodiments of the utility model, not all of the embodiments. Based on the embodiments of the utility model, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the utility model.

[0036] Unless otherwise defined, the technical terms or scientific terms used in the present invention shall have the usual meanings understood by persons with ordinary skills in the field to which the present invention belongs. The words "first", "second" and similar words used in the present invention do not indicate any order, quantity or importance, but are only used to distinguish different components. Similarly, words such as "one" or "one" do not indicate quantity restrictions, but indicate the existence of at least one. Words such as "connect" or "connected" are not limited to physical or mechanical connections, but may include electrical connections, whether direct or indirect. "Up", "down", "left", "right" and the like are only used to indicate relative positional relationships. When the absolute position of the object being described changes, the relative positional relationship also changes accordingly.

[0037] Reference Figures 1 to 11 , a high-voltage transformer and inductor integrated structure for an on-board charger of an electric vehicle, comprising an inductor 1, a high-voltage transformer 2 and a housing 3.

[0038] The primary coil 10 is wound with a copper wire on the transformer frame 2-2 and the inductor frame 1-2 to connect the high-voltage transformer 2 and the inductor 1 in series;

[0039] A wire clamping groove 8 is provided at the upper end of one side of the transformer skeleton 2-2, and a wire passing groove 7 is provided at the upper end of the other side of the transformer skeleton 2-2; a longitudinal clamping buckle Ⅰ15-1 is provided at one corner of the transformer skeleton 2-2 in a direction parallel to the axial direction of the transformer skeleton 2-2, and a transverse clamping buckle Ⅱ15-2, a transverse clamping buckle Ⅲ15-3 and a transverse clamping buckle Ⅳ15-4 perpendicular to the direction of the longitudinal clamping buckle Ⅰ15-1 are provided at the other three corners; accordingly, a longitudinal clamping ring 13-1 is provided at the edge of the mounting groove 12 at a position corresponding to the longitudinal clamping buckle Ⅰ15-1, and a transverse clamping ring Ⅰ13-1, a transverse clamping ring Ⅱ13-2, a transverse clamping ring Ⅲ13-3 and a transverse clamping ring Ⅳ13-4 are provided at positions corresponding to the transverse clamping buckle Ⅱ15-2, the transverse clamping buckle Ⅲ15-3 and the transverse clamping buckle Ⅳ15-4; in this way, the entire integrated structure can be ensured to be relatively stable and easy to disassemble;

[0040] The wire heads and tails of the primary coil 10 and the secondary coil 11 are fixed by corresponding wire clamping grooves 8. The wire tail of the primary coil 10 is limited in position by the wire passing groove 7.

[0041] In order to ensure the thermal conductivity and bonding effect, the transformer skeleton 2-2, the transformer air gap sheet 2-4, the inductor skeleton 1-2 and the inductor air gap sheet 1-4 are made of plastic with a thermal conductivity of ≥2.5W / mK, and are bonded with a soft material adhesive with a thermal conductivity of ≥1.0W / mK; the bonding glue between the surface of the inductor core 1-1 and the surface of the transformer core 1-2 and the heat sink 4 is made of a thermal conductive glue with a thermal conductivity of ≥1.0W / mK, such as Figure 2 , Figures 6 to 9 As shown, the transformer air gap sheet 2-4 and the transformer magnetic sheet 2-3 are first glued to the transformer magnetic core middle column 2-1-1 with a high thermal conductivity soft material, and the bonding sequence is the transformer magnetic core 2-1 middle column, the transformer air gap sheet 2-4, the transformer magnetic sheet 2-3, the transformer air gap sheet 2-4, the transformer magnetic sheet 2-3, the transformer air gap sheet 2-4, the transformer magnetic sheet 2-3, the transformer air gap sheet 2-4, the transformer magnetic core middle column 2-1-1, and the two transformer magnetic core end faces 2-1-2 are glued together by hard glue; the inductor air gap sheet 2-4 and the transformer magnetic core middle column 2-1-1 are first glued to the transformer magnetic core end faces 2-1-2 by hard glue; The gap sheet 1-4 and the inductor magnetic sheet 1-3 are bonded to the middle column of the inductor core 1 by using a soft material adhesive with a thermal conductivity of ≥1.0W / mK. The bonding order is: the middle column 1-1-1 of the inductor core, the inductor air gap sheet 1-4, the inductor magnetic sheet 1-3, the inductor air gap sheet 1-4, the inductor magnetic sheet 1-3, the inductor air gap sheet 1-4, the transformer core 2-1, and the inductor core end face 1-1-2 and the transformer core bottom face 2-1-3 are bonded together by a hard material adhesive.

[0042] The high-voltage transformer 2 is installed between two transformer cores 2-1 by matching the transformer core matching hole 2-2-1 on the transformer skeleton 2-2 with the transformer core middle column 2-1-1. The inductor 1 is installed between the inductor core 1-1 and the transformer core 2-1 by matching the inductor core matching hole 1-2-1 on the inductor skeleton 1-2 with the inductor core middle column 1-1-1.

[0043] The aluminum alloy heat sink 4 is adhered to the surface of the inductor core 1-2 and the surface of the transformer core 2-1 by means of thermal conductive adhesive to increase the heat dissipation efficiency.

[0044] During installation, first install the transverse clip III 15-3 and transverse clip IV 15-4 on the transformer skeleton 2-2 into the transverse clip ring III 13-3 and transverse clip ring IV 13-4 of the shell 3, and then apply downward force to the shell 3. The material undergoes elastic deformation to allow the longitudinal clip I 15-1 and transverse clip II 15-2 to be respectively engaged with the longitudinal clip ring I 13-1 and transverse clip ring II 13-2. After being engaged, they are firmly fastened and not easy to come off. If it is necessary to remove the shell 3, first push the transverse clip ring II 13-2 on the shell 3 outward to make the transverse clip II 15-2 come off, and then push the shell 3 in the direction where the longitudinal clip I 15-1 comes off to remove the shell 3.

[0045] In order to ensure that the connection terminals Ⅰ6-1 and Ⅱ6-2 can only be inserted in one direction and cannot be pulled out, inverted teeth are respectively provided on both sides of the insertion ends of the connection terminals Ⅰ6-1 and Ⅱ6-2; firstly, the end of the primary coil 10 is welded to the wire hole Ⅰ6-1-2 of the connection terminal Ⅰ6-1, and the end of the secondary coil 11 is welded to the wire hole Ⅱ6-2-2 of the connection terminal Ⅱ6-2, and then the plug ends of the connection terminals Ⅰ6-1 and Ⅱ6-2 are inserted from the hollow of the support plate 5-3 of the terminal connection seat 5, and the connection of the connection terminal Ⅰ6-1 ...Ⅱ6-2. Hole I6-1-1 and connection hole II6-2-1 of connection terminal II6-2 are respectively aligned with terminal mounting hole 5-1 of terminal connection base 5. At this point, connection terminal I6-1 and connection terminal II6-2 are fixed on terminal connection base 5 in a reverse gear manner. The input and output ends of the high-voltage transformer can be directly connected to the vehicle charger by means of screw fastening or the like. Since the connection terminals are installed on the terminal connection base 5, the relative position relationship of the holes is fixed. Therefore, when the input and output of the high-voltage transformer are connected to the vehicle charger, the four holes can be aligned at the same time, thereby improving assembly efficiency.

[0046] On the terminal connection base 5, there is a baffle 5-2 between each two adjacent terminal mounting holes 5-1, which can ensure the safety distance between the connection terminal I 6-1 and the connection terminal II 6-2 and the transformer core 2-1. There is a mounting through hole 14 on the housing 3, which can directly install the high-voltage transformer 2 and the inductor 1 integrated component in the vehicle charger;

[0047] like Figure 1 After the connection terminal Ⅰ 6-1 and the connection terminal Ⅱ 6-2 are welded to the tail end of the coil, they are wrapped with a heat shrink tube 9 to ensure the safety distance.

Claims

1. A high-voltage transformer and inductor integrated structure for an on-board charger of an electric vehicle, comprising an inductor (1) and a high-voltage transformer (2), wherein the inductor (1) and the high-voltage transformer (2) are connected in series by a primary coil (10) wound by a whole copper wire, and characterized in that: It also comprises a housing (3) and a heat sink (4); a mounting groove (12) matching the shape of the high-voltage transformer (2) is provided on the upper end surface of the housing (3); the integrated structure of the inductor (1) and the high-voltage transformer (2) is arranged in the housing (3) through the mounting groove (12); the heat sink (4) is arranged around the surface of the transformer magnetic core (2-1) and the inductor magnetic core (1-1); the two connecting terminals I (6-1) of the primary coil (10) and the two connecting terminals II (6-2) of the secondary coil (11) are respectively connected to the terminal mounting holes (5-1) on the terminal connection seat (5); A wire clamping groove (8) is provided at the upper end of one side of the transformer frame (2-2), and a wire passing groove (7) is provided at the upper end of the other side of the transformer frame (2-2); a buckle (15) is provided on the transformer frame (2-2); a clamping ring (13) is provided at the edge of the mounting groove (12) and at a position corresponding to the buckle (15); the starting end and the tail end of the primary coil (10) and the secondary coil (11) are respectively passed through the corresponding wire clamping groove (8) for fixation; the tail end of the primary coil (10) wound on the inductor frame (1-2) and the transformer frame (2-2) passes through a corresponding position of the wire passing groove (7), and the buckle (15) and the clamping ring (13) are matched.

2. The high-voltage transformer and inductor integrated structure for an on-board charger for electric vehicles as claimed in claim 1, characterized in that: The support plate (5-3) of the terminal connection seat (5) is a hollow plate; the position of the terminal mounting hole (5-1) on the terminal connection seat (5) corresponds to the position of the connection terminal of the on-board charger; and a baffle (5-2) is provided between every two adjacent terminal mounting holes (5-1).

3. The high-voltage transformer and inductor integrated structure for an on-board charger for an electric vehicle as claimed in claim 1, characterized in that: The connection terminal I (6-1) and the connection terminal II (6-2) are both L-shaped, and inverted teeth are respectively provided on both sides of the insertion ends of the connection terminal I (6-1) and the connection terminal II (6-2).

4. The high-voltage transformer and inductor integrated structure for an on-board charger for an electric vehicle as claimed in claim 1, characterized in that: There are four buckles (15), namely longitudinal buckle I (15-1), transverse buckle II (15-2), transverse buckle III (15-3) and transverse buckle IV (15-4), which are respectively arranged at four corners of the transformer frame (2-2), the direction of the longitudinal buckle I (15-1) is parallel to the axial direction of the transformer frame (2-2), and the directions of the transverse buckle II (15-2), transverse buckle III (15-3) and transverse buckle IV (15-4) are perpendicular to the longitudinal buckle I (15-1); correspondingly, there are four buckles (13), namely longitudinal buckle I (13-1), transverse buckle III (15-3) and transverse buckle IV (15-4). Ⅱ (13-2), transverse snap ring III (13-3) and transverse snap ring IV (13-4), which are respectively arranged at the four corners of the installation groove (12); the direction of the longitudinal snap ring I (13-1) is perpendicular to the transverse snap ring II (13-2), transverse snap ring III (13-3) and transverse snap ring IV (13-4); the longitudinal snap ring I (15-1), transverse snap ring II (13-2), transverse snap ring III (13-3) and transverse snap ring IV (13-4) respectively correspond to the positions of the longitudinal snap ring I (13-1), transverse snap ring II (13-2), transverse snap ring III (13-3) and transverse snap ring IV (13-4).

5. The high-voltage transformer and inductor integrated structure for an on-board charger for an electric vehicle as claimed in claim 1, characterized in that: The transformer skeleton (2-2), the transformer air gap sheet (2-4), the inductor skeleton (1-2) and the inductor air gap sheet (1-4) are made of plastic with a thermal conductivity of ≥2.5W / mK; the adhesive between the transformer magnetic sheet (2-3) and the transformer air gap sheet (2-4) and between the inductor magnetic sheet (1-3) and the inductor air gap sheet (1-4) is made of a soft material adhesive with a thermal conductivity of ≥1.0W / mK; the adhesive between the surface of the inductor magnetic core (1-1) and the surface of the transformer magnetic core (2-1) and the heat sink (4) is made of a thermal conductive adhesive with a thermal conductivity of ≥1.0W / mK.

Images