High-power flat transformer

Abstract

The embodiment of the utility model discloses a high-power flat transformer, the high-power flat transformer comprises a magnetic core, a copper sheet and a wire cake, the magnetic core comprises a first core body, a second core body and a middle column, the first core body and the second core body enclose to form a mounting cavity, the middle column is connected to the first core body or the second core body, the copper sheet is mounted in the mounting cavity and is sleeved on the middle column, and the wire cake is arranged on the copper sheet. The copper sheet comprises a first part and a second part which are integrally bent, a mounting groove is formed between the first part and the second part, the wire cake is mounted in the first part, the second part and the mounting groove, and the copper sheet is integrally arranged and does not need to be welded, so that the quality and the reliability of the transformer cannot be influenced by welding; the use stability of the transformer is improved.

Description

Technical Field

[0001] The utility model relates to the technical field of transformers, in particular to a high-power flat transformer. Background Art

[0002] As the installation space continues to shrink, the size of the transformer has become a headache in many design schemes. Therefore, the existing design scheme uses copper sheet splicing to make high-power transformers. This requires the copper sheets to be spliced ​​and welded piece by piece to compress the distance between the windings. However, the splicing process requires welding technology, which also increases the risk of loose welding, especially in high-current and high-power applications. The local resistance of the welding part will be higher than that of the copper sheet. The size of the welding area determines the quality and reliability of the transformer, thereby affecting the stability of the transformer. Utility Model Content

[0003] Based on this, it is necessary to provide a high-power flat transformer, which aims to solve the problem that the existing design adopts the copper sheet splicing method to make a high-power transformer, which requires the copper sheets to be spliced ​​and welded piece by piece to compress the distance between the windings. However, the splicing process requires welding technology, which also increases the risk of weak welding, especially in high-current and high-power applications. The local resistance of the welding part will be higher than that of the copper sheet. The size of the welding area determines the quality and reliability of the transformer, thereby affecting the technical problem of the stability of the transformer.

[0004] The utility model provides a high-power flat transformer, which comprises a magnetic core, a copper sheet and a coil, wherein the magnetic core comprises a first core body, a second core body and a middle column, wherein the first core body and the second core body are enclosed to form an installation cavity, wherein the middle column is connected to the first core body or the second core body, wherein the copper sheet is installed in the installation cavity and sleeved with the middle column, wherein the copper sheet comprises a first part and a second part which are bent integrally, wherein an installation groove is provided between the first part and the second part, and wherein the coil is installed in the first part, the second part and the installation groove.

[0005] In one embodiment, the first part is provided with a first mounting surface, the second part is provided with a second mounting surface, the first mounting surface is provided with a first mounting hole, the first mounting hole is used for external mounting, and the second mounting surface is provided with a second mounting hole, the second mounting hole is used for external mounting.

[0006] In one embodiment, the bobbin includes a plurality of coils, and each coil is stacked in the first portion, the mounting groove, and the second portion to form a winding.

[0007] In one embodiment, the coil further includes a fixing member, and a plurality of the fixing members are provided to fix the coils respectively.

[0008] In one embodiment, the coil further includes a connector, which connects the coils and is used to connect the circuit.

[0009] In one embodiment, the coil further includes a plurality of insulating films, each of which is connected to each of the coils and is used to isolate each of the coils.

[0010] In one embodiment, the high-power flat transformer further includes a plurality of adhesive backing films, each of which is respectively connected to the first portion, the slot wall of the first mounting slot and the second portion, and is used to isolate the copper sheet and each of the coils.

[0011] In one embodiment, each of the adhesive films is provided with a through hole, and the center column passes through the through hole.

[0012] In one embodiment, the high-power flat transformer further includes a sleeve, which is sleeved on the middle column and used to isolate the copper sheet and the coil.

[0013] In one embodiment, the high-power flat transformer also includes an insulating plate and an adhesive-backed insulating tape, the insulating plate is provided with an inner hole, the sleeve passes through the inner hole, the adhesive-backed insulating tape is connected to the wall of the magnetic core, and the insulating plate and the adhesive-backed insulating tape are both used to isolate the magnetic core and the coil.

[0014] Implementing the embodiments of the present utility model will have the following beneficial effects:

[0015] The high-power flat transformer of the utility model is adopted. The first core body and the second core body of the high-power flat transformer are enclosed to form an installation cavity. The middle column is connected to the first core body or the second core body. The copper sheet is installed in the installation cavity and the middle column is sleeved so that the copper sheet can be stably installed. The copper sheet includes a first part and a second part that are bent integrally. A mounting groove is provided between the first part and the second part. The wire coil is installed in the first part, the second part and the mounting groove. Since the copper sheet is arranged as an integral whole, there is no need to weld the copper sheet, so that the quality and reliability of the transformer will not be affected by welding, thereby improving the stability of the transformer. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the embodiments of the utility model or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the utility model. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0017] in:

[0018] Figure 1 FIG. 1 is an axonometric diagram of a high-power flat transformer in one embodiment.

[0019] Figure 2 for Figure 1 Exploded diagram of a high power flat transformer shown.

[0020] Figure 3 for Figure 2 The schematic diagram of the neutral wire cake of the high-power flat transformer is shown.

[0021] Figure 4 for Figure 2 Schematic diagram of the copper sheet and adhesive film in the high-power flat transformer shown.

[0022] Figure 5 for Figure 2 Schematic diagram of the copper sheet in the high-power flat transformer shown.

[0023] Reference numerals:

[0024] 1. magnetic core; 11. first core body; 12. second core body; 13. middle column;

[0025] 2. Copper sheet; 21. First part; 211. First mounting surface; 212. First mounting hole; 22. Second part; 221. Second mounting surface; 222. Second mounting hole; 23. Mounting groove;

[0026] 3. Coil; 31. Coil; 32. Fixing piece; 33. Connector; 34. Insulating film;

[0027] 4. Adhesive film; 41. Through hole;

[0028] 5. Sleeve; 6. Insulation plate; 61. Inner hole; 7. Adhesive insulating tape;

[0029] 100. Installation cavity. DETAILED DESCRIPTION

[0030] 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 only 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.

[0031] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, further definition and explanation thereof is not required in subsequent drawings.

[0032] In the description of the present utility model, it should be noted that if the terms "upper", "lower", "inside", "outside", etc. appear, the orientation or position relationship indicated is based on the orientation or position relationship shown in the accompanying drawings, or is the orientation or position relationship in which the utility model product is usually placed when used. It is only for the convenience of describing the utility model and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it cannot be understood as a limitation on the present utility model.

[0033] In addition, the terms “first”, “second”, etc., if used, are merely used to distinguish between the descriptions and should not be understood as indicating or implying relative importance.

[0034] It should be noted that, in the absence of conflict, the features in the embodiments of the present invention may be combined with each other.

[0035] With the rapid development of the electric vehicle market, the demand for high-power transformers continues to increase. At the same time, the market has also put forward higher requirements on the performance, efficiency, reliability and other aspects of high-power transformers. For example:

[0036] High efficiency: The transformer needs to have high efficiency to reduce energy loss and improve the overall efficiency of the OBC system. A high-efficiency transformer can speed up the charging task and reduce system energy consumption.

[0037] Miniaturization and lightweight: With the rapid development of electric vehicles, the requirements for OBC volume and weight are getting higher and higher. The transformer must be miniaturized, lightweight, and have high power density to meet the system space and weight limitations.

[0038] High safety: The transformer needs to have over-current, over-voltage, over-heating and other protection functions to prevent system failure and damage. At the same time, the transformer design must also take into account electromagnetic compatibility to avoid interference with other electronic equipment.

[0039] High reliability: The transformer is required to consider various harsh operating environments during the design process, such as high temperature, low temperature, humidity, vibration, etc. to ensure that it can work properly under various conditions.

[0040] Please combine Figures 1 to 5 Now, the high-power flat transformer provided by the utility model is described.

[0041] The high-power flat transformer includes a magnetic core 1, a copper sheet 2 and a coil 3. The magnetic core 1 includes a first core body 11, a second core body 12 and a middle column 13. The first core body 11 and the second core body 12 enclose an installation cavity 100. The middle column 13 is connected to the first core body 11 or the second core body 12. The copper sheet 2 is installed in the installation cavity 100 and is sleeved with the middle column 13. The copper sheet 2 includes a first part 21 and a second part 22 that are bent integrally. A mounting groove 23 is provided between the first part 21 and the second part 22. The coil 3 is installed in the first part 21, the second part 22 and the mounting groove 23.

[0042] It can be understood that the first core 11 and the second core 12 of the high-power flat transformer enclose a mounting cavity 100, the middle column 13 is connected to the first core 11 or the second core 12, the copper sheet 2 is installed in the mounting cavity 100, and the middle column 13 is sleeved so that the copper sheet 2 can be firmly installed. The copper sheet 2 includes a first part 21 and a second part 22 that are bent integrally, and a mounting groove 23 is provided between the first part 21 and the second part 22. The coil 3 is installed in the first part 21, the second part 22 and the mounting groove 23. Since the copper sheet 2 is integrally arranged, there is no need to weld the copper sheet 2, so that the quality and reliability of the transformer will not be affected by welding, thereby improving the stability of the transformer.

[0043] In addition, by using the integrated copper sheet 2 as the winding of the transformer, the windings of the transformer can be closely fitted to each other.

[0044] It should be added that the mounting groove 23 needs to be designed according to the thickness of the coil 3, and be consistent with the thickness of the coil 3, so as to minimize the gap between the copper sheet 2 and the coil 3, maximize coupling, reduce leakage flux, reduce electromagnetic interference, and reduce transformer temperature rise.

[0045] In this embodiment, the first part 21 is provided with a first mounting surface 211, the second part 22 is provided with a second mounting surface 221, the first mounting surface 211 is provided with a first mounting hole 212, the first mounting hole 212 is used for external mounting, and the second mounting surface 221 is provided with a second mounting hole 222, the second mounting hole 222 is used for external mounting. Specifically, the high-power flat transformer also includes a plurality of fasteners, after the first mounting surface 211 and the second mounting surface 221 are respectively in contact with the external component, the plurality of fasteners respectively penetrate the first mounting hole 212 and the second mounting hole 222, and are threadedly connected with the external component.

[0046] In one embodiment, if Figure 2 and Figure 3 As shown, the coil 3 includes a plurality of coils 31, and each coil 31 is stacked in the first part 21, the mounting groove 23 and the second part 22 to form a winding. Each coil 31 is wound with a film-wrapped wire to reduce the loss contributed by the AC skin effect. It has its own insulating film 34, which is secondary insulation to prevent high-voltage breakdown. By arranging three coils 31 in parallel and stacking them with the first part 21, the mounting groove 23 and the second part 22, a close fit is achieved, the maximum coupling coefficient is achieved, the leakage inductance of the transformer is minimized, the electromagnetic interference is reduced, the temperature rise of the transformer is reduced, and the efficiency of the transformer is also improved.

[0047] By combining the above methods, the winding window of the magnetic core 1 can be utilized to the maximum extent, the volume and height of the transformer can be reduced, and miniaturization and lightness can be achieved to the greatest extent possible.

[0048] In one embodiment, the inner diameters of the copper sheet 2 and the wire coil 3 may be rectangular, elliptical or polygonal.

[0049] The copper sheet 2 is preferably a high current winding, but it can also be made of aluminum or other conductive materials according to actual needs.

[0050] The material of the magnetic core 1 is preferably manganese zinc or other materials with high magnetic permeability.

[0051] The coil 3 may be made of silk-covered wire or other multi-strand Litz wire to reduce AC loss.

[0052] In this embodiment, the coil 3 further includes a fixing member 32, and a plurality of fixing members 32 are provided, and the fixing members 32 are respectively fixed to the coil 31. By providing the fixing member 32, the fixing member 32 can be a fixing tie to prevent the coil 3 from being scattered.

[0053] Furthermore, the coil 3 also includes a connector 33, which is connected to each coil 31 and used to connect the circuit, so that each coil 31 can be energized.

[0054] In one embodiment, if Figure 2 As shown, the coil 3 further includes a plurality of insulating films 34, each of which is connected to each coil 31 and is used to isolate each coil 31. By providing the insulating films 34, insulation between the coils 31 is achieved.

[0055] In one embodiment, if Figure 4 As shown, the high-power flat transformer also includes a plurality of adhesive films 4, each of which is respectively connected to the first portion 21, the slot wall of the first mounting slot 23 and the second portion 22, and is used to isolate the copper sheet 2 and each coil 31. By providing the adhesive film 4, the copper sheet 2 and the coil 3 can be secondary isolated to improve the withstand voltage performance.

[0056] In this embodiment, each adhesive film 4 is provided with a through hole 41, and the middle column 13 is penetrated with the through hole 41. In this way, the adhesive film 4 can be attached to the copper sheet 2.

[0057] In one embodiment, if Figure 2 As shown, the high-power flat transformer also includes a sleeve 5, which is sleeved on the middle column 13 and is used to isolate the copper sheet 2 and the coil 3. By providing the sleeve 5, the insulation between the middle column 13 and the copper sheet 2 and the coil 3 is achieved.

[0058] In one embodiment, continue as Figure 2 As shown, the high-power flat transformer also includes an insulating plate 6 and an adhesive-backed insulating tape 7. The insulating plate 6 is provided with an inner hole 61, and the sleeve 5 is provided with the inner hole 61. The adhesive-backed insulating tape 7 is connected to the wall surface of the magnetic core 1. The insulating plate 6 and the adhesive-backed insulating tape 7 are both used to isolate the magnetic core 1 and the coil 3. By providing the insulating plate 6 and the adhesive-backed insulating tape 7, the magnetic core 1 and the coil 3 and the copper sheet 2 can be insulated. By providing the inner hole 61, the insulating plate 6 can be sleeved on the sleeve 5.

[0059] The technical features of the above-described embodiments may be arbitrarily combined. To make the description concise, not all possible combinations of the technical features in the above-described embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0060] The above disclosure is only a preferred embodiment of the present invention, and certainly cannot be used to limit the scope of rights of the present invention. Therefore, equivalent changes made according to the claims of the present invention are still within the scope covered by the present invention.

Claims

1. A high-power flat transformer, characterized in that: The high-power flat transformer includes a magnetic core, a copper sheet and a coil. The magnetic core includes a first core body, a second core body and a middle column. The first core body and the second core body are surrounded by a mounting cavity. The middle column is connected to the first core body or the second core body. The copper sheet is installed in the mounting cavity and sleeved with the middle column. The copper sheet includes a first part and a second part that are bent integrally. A mounting groove is provided between the first part and the second part. The coil is installed in the first part, the second part and the mounting groove.

2. The high-power flat transformer according to claim 1, characterized in that: The first part is provided with a first mounting surface, the second part is provided with a second mounting surface, the first mounting surface is provided with a first mounting hole, the first mounting hole is used for external mounting, the second mounting surface is provided with a second mounting hole, the second mounting hole is used for external mounting.

3. The high-power flat transformer according to claim 1, characterized in that: The bobbin includes a plurality of coils, and each of the coils is stacked in the first portion, the mounting groove, and the second portion to form a winding.

4. The high-power flat transformer according to claim 3, characterized in that: The coil also includes a fixing piece, and a plurality of the fixing pieces are provided to fix the coils respectively.

5. The high-power flat transformer according to claim 3, characterized in that: The coil also includes a connector, which is connected to each coil and is used to connect the circuit.

6. The high-power flat transformer according to claim 3, characterized in that: The coil also includes a plurality of insulating films, each of which is connected to each of the coils and is used to isolate each of the coils.

7. The high-power flat transformer according to claim 3, characterized in that: The high-power flat transformer also includes a plurality of adhesive films, each of which is respectively connected to the first part, the slot wall of the first installation slot and the second part, and is used to isolate the copper sheet and each of the coils.

8. The high-power flat transformer according to claim 7, characterized in that: Each of the adhesive backing films is provided with a through hole, and the center column passes through the through hole.

9. The high-power flat transformer according to claim 1, characterized in that: The high-power flat transformer also includes a sleeve, which is sleeved on the middle column and used to isolate the copper sheet and the coil.

10. The high-power flat transformer according to claim 9, characterized in that: The high-power flat transformer also includes an insulating plate and an adhesive-backed insulating tape. The insulating plate is provided with an inner hole, the sleeve passes through the inner hole, the adhesive-backed insulating tape is connected to the wall surface of the magnetic core, and the insulating plate and the adhesive-backed insulating tape are both used to isolate the magnetic core and the coil.

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