Magnetic integrated transformer

Abstract

The utility model provides a magnetic integrated transformer. The magnetic integrated transformer comprises an upper magnetic core, a lower magnetic core, a primary winding, a secondary winding, a magnetic core middle column, a first magnetic core side column and a second magnetic core side column. The upper magnetic core and the lower magnetic core are stacked in the first direction. The magnetic core middle column, the first magnetic core side column and the second magnetic core side column are located between the upper magnetic core and the lower magnetic core. The magnetic core middle column is located between the first magnetic core side column and the second magnetic core side column in the second direction perpendicular to the first direction. After the magnetic core middle column, the first magnetic core side column and the second magnetic core side column are sectioned in the second direction, the cross sectional area of the magnetic core middle column is defined as S1, the cross sectional area of the first magnetic core side column is defined as S2, the cross sectional area of the second magnetic core side column is defined as S3, and S1 is larger than or equal to two times of S2 and two times of S3. One of the primary winding and the secondary winding surrounds the first magnetic core side column, and the other one surrounds the second magnetic core side column. According to the magnetic integrated transformer, miniaturization is achieved, and meanwhile the magnetic flux utilization rate is improved.

Description

Technical Field

[0001] The present application relates to the field of transformers, and in particular to a magnetic integrated transformer. Background Art

[0002] As the switching power supply has higher requirements on volume, transformers and resonant inductors, as core components of the switching power supply, also put forward higher requirements on the space occupied by transformers and resonant inductors. Magnetic integration technology is a power electronics technology that has received widespread attention in recent years. Conventional magnetic integrated transformers are designed with transformers and resonant circuits as separate parts, resulting in the magnetic integrated transformer occupying a large volume in the switching power supply, making it difficult to achieve miniaturization of the magnetic integrated transformer. In addition, the area of ​​the middle column and the side column of the magnetic core of the existing magnetic integrated transformer is the same, resulting in a low magnetic flux utilization rate of the magnetic integrated transformer and a low power density of the magnetic integrated transformer. Utility Model Content

[0003] The present application provides a miniaturized magnetic integrated transformer capable of improving magnetic flux utilization.

[0004] A magnetic integrated transformer comprises: an upper magnetic core, a lower magnetic core, a primary winding, a secondary winding, a magnetic core center column, a first magnetic core side column and a second magnetic core side column, wherein the upper magnetic core and the lower magnetic core are arranged in a superimposed manner along a first direction, the magnetic core center column, the first magnetic core side column and the second magnetic core side column are located between the upper magnetic core and the lower magnetic core, and along a second direction perpendicular to the first direction, the magnetic core center column is located between the first magnetic core side column and the second magnetic core side column, after the magnetic core center column, the first magnetic core side column and the second magnetic core side column are cut along the second direction, the cross-sectional area of ​​the magnetic core center column is defined as S1, the cross-sectional area of ​​the first magnetic core side column is defined as S2, and the cross-sectional area of ​​the second magnetic core side column is defined as S3, S1 is greater than or equal to 2 times S2 and 2 times S3, and one of the primary winding and the secondary winding is wrapped around the first magnetic core side column, and the other is wrapped around the second magnetic core side column.

[0005] Furthermore, one end of the middle column of the magnetic core is retracted relative to the edge of the lower magnetic core to form an escape portion for the primary winding and / or the secondary winding to pass through.

[0006] Further, the primary winding includes a first primary winding, the secondary winding includes a first secondary winding, the first primary winding and the first secondary winding are wound around the first magnetic core side column, and the first primary winding and the first secondary winding are superimposed along the first direction.

[0007] Further, the primary winding includes a second primary winding, the secondary winding includes a second secondary winding, the second primary winding and the second secondary winding are wound around the second magnetic core side column, and one of the second primary winding and the second secondary winding is wound around the outside of the other.

[0008] Further, the first primary winding is connected in series with the second primary winding, and the first secondary winding is connected in series with the second secondary winding.

[0009] Furthermore, the outer surface of the primary winding and / or the secondary winding is provided with a coating.

[0010] Furthermore, the magnetic core center column includes: an upper magnetic core center column and a lower magnetic core center column stacked along the first direction, the upper magnetic core center column and the upper magnetic core are fixed, the lower magnetic core center column and the lower magnetic core are fixed, and a first air gap is provided between the upper magnetic core center column and the lower magnetic core center column.

[0011] Furthermore, the first magnetic core side column includes: a first upper magnetic core side column and a first lower magnetic core side column stacked along the first direction, the first upper magnetic core side column and the upper magnetic core are fixed, the first lower magnetic core side column and the lower magnetic core are fixed, and a second air gap is provided between the first upper magnetic core side column and the first lower magnetic core side column.

[0012] Furthermore, the second magnetic core side column includes: a second upper magnetic core side column and a second lower magnetic core side column stacked along the first direction, the second upper magnetic core side column and the upper magnetic core are fixed, the second lower magnetic core side column and the lower magnetic core are fixed, and a second air gap is provided between the second upper magnetic core side column and the second lower magnetic core side column.

[0013] Further, along the first direction, a height of the first air gap is greater than a height of the second air gap.

[0014] In some embodiments, the magnetic core center column of the above technical solution is arranged between the first magnetic core side column and the second magnetic core side column, one of the primary winding and the secondary winding is wrapped around the first magnetic core side column, and the other is wrapped around the second magnetic core side column. Compared with the split structure of the existing magnetic integrated transformer, the magnetic integrated transformer of the present application has a simple structure and is light and compact, realizing the miniaturization of the magnetic integrated transformer; at the same time, the cross-sectional area of ​​the magnetic core center column is greater than or equal to the cross-sectional area of ​​the first magnetic core side column and the cross-sectional area of ​​the second magnetic core side column, thereby improving the magnetic flux utilization and power density of the magnetic integrated transformer. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 is a schematic diagram of a magnetic integrated transformer according to an exemplary embodiment of the present application.

[0016] Figure 2 yes Figure 1 The cross-sectional schematic diagram of the magnetic integrated transformer along the AA line is shown.

[0017] Figure 3 yes Figure 1 Exploded view of the magnetics integrated transformer shown.

[0018] Figure 4 yes Figure 1 The schematic diagram of the magnetic integrated transformer shown is after omitting the primary winding and the secondary winding.

[0019] Figure 5 yes Figure 4 Side view of the magnetic integrated transformer shown.

[0020] Explanation of the accompanying drawings: 1. upper magnetic core; 2. lower magnetic core; 3. core center column; 30. avoidance portion; 31. upper magnetic core center column; 32. lower magnetic core center column; 41. first magnetic core side column; 411. first upper magnetic core side column; 412. first lower magnetic core side column; 42. second magnetic core side column; 421. second upper magnetic core side column; 422. second lower magnetic core side column; 5. first air gap; 6. second air gap; 7. primary winding; 71. first primary winding; 72. second primary winding; 8. secondary winding; 81. first secondary winding; 82. second secondary winding; 9. coating. DETAILED DESCRIPTION

[0021] The embodiments of the present application provide a magnetic integrated transformer for use in the fields of switching power supplies, power electronics, signal transmission, industrial control, etc., to perform voltage conversion, voltage regulation, etc., to ensure the performance and reliability of the circuit.

[0022] See also Figure 1 to Figure 2 As shown, the magnetic integrated transformer includes: an upper magnetic core 1, a lower magnetic core 2, a primary winding 7, a secondary winding 8, a magnetic core center column 3, a first magnetic core side column 41 and a second magnetic core side column 42. The upper magnetic core 1 and the lower magnetic core 2 are stacked along a first direction, the magnetic core center column 3, the first magnetic core side column 41 and the second magnetic core side column 42 are located between the upper magnetic core 1 and the lower magnetic core 2, and along a second direction perpendicular to the first direction, the magnetic core center column 3 is located between the first magnetic core side column 41 and the second magnetic core side column 42.

[0023] The arrangement of the core center column 3, the first core side column 41 and the second core side column 42 makes the magnetic flux more evenly distributed between the upper core 1 and the lower core 2, reduces local saturation, and improves the overall magnetic properties of the magnetic integrated transformer; at the same time, the arrangement of the core center column 3, the first core side column 41 and the second core side column 42 has a simple and compact structure, which effectively reduces the space occupied by the magnetic integrated transformer in the switching power supply and realizes the miniaturization of the magnetic integrated transformer.

[0024] In some embodiments, the upper magnetic core 1 is an integrated structure with the magnetic core middle column 3 , the first magnetic core side column 41 , and the second magnetic core side column 42 .

[0025] Optionally, the upper magnetic core 1 is fixed to the magnetic core middle column 3 , the first magnetic core side column 41 , and the second magnetic core side column 42 by welding, snap connection, adhesive connection, or the like.

[0026] In some embodiments, the lower magnetic core 2 is an integrated structure with the magnetic core middle column 3 , the first magnetic core side column 41 , and the second magnetic core side column 42 .

[0027] Optionally, the lower magnetic core 2 is fixed to the magnetic core middle column 3 , the first magnetic core side column 41 , and the second magnetic core side column 42 by welding, snap connection, adhesive connection, or the like.

[0028] See also Figure 3 After cutting the core center column 3, the first core side column 41 and the second core side column 42 along the second direction, the cross-sectional area of ​​the core center column 3 is defined as S1, the cross-sectional area of ​​the first core side column 41 is defined as S2, and the cross-sectional area of ​​the second core side column 42 is defined as S3. S1 is greater than or equal to 2 times S2 and 2 times S3. At this time, S1 is the upper surface area of ​​the core center column 3 after cutting, S2 is the upper surface area of ​​the first core side column 41 after cutting, and S3 is the upper surface area of ​​the second core side column 42 after cutting. The magnetic flux load capacity of the core center column 3 is increased, and the magnetic flux transmission capacity of the entire magnetic integrated transformer is improved, thereby improving the power density and efficiency of the magnetic integrated transformer.

[0029] In some embodiments, the second direction may also be Figure 1 In the direction of the arrow in the figure, after cutting the core middle column 3, the first core side column 41 and the second core side column 42 along the second direction, S1 is Figure 2 The cross-sectional area of ​​the core center column 3 after cutting is shown, S2 is the cross-sectional area of ​​the first core side column 41 , and S3 is the cross-sectional area of ​​the second core side column 42 .

[0030] One of the primary winding 7 and the secondary winding 8 is wound around the first magnetic core side column 41, and the other is wound around the second magnetic core side column 42. The primary winding 7 and the secondary winding 8 are directly wound around the first magnetic core side column 41 or the second magnetic core side column 42. There is no need to set up an additional magnetic circuit to connect the primary winding 7 and the secondary winding 8, which simplifies the magnetic circuit structure and realizes the miniaturization of the magnetic integrated transformer.

[0031] In some embodiments, the primary winding 7 is wound on the first magnetic core side column 41 , and the secondary winding 8 is wound on the second magnetic core side column 42 .

[0032] In some embodiments, the secondary winding 8 is wound on the first magnetic core side column 41 , and the primary winding 7 is wound on the second magnetic core side column 42 .

[0033] In some embodiments, a primary winding 7 and a secondary winding 8 are wound around the first magnetic core side column 41 , and a primary winding 7 and a secondary winding 8 are also wound around the second magnetic core side column 42 .

[0034] One end of the core middle column 3 is retracted relative to the edge of the lower core 2 to form an escape portion 30 for the primary winding 7 and / or the secondary winding 8 to pass through. The setting of the escape portion provides space for the lead-out and insertion of the primary winding 7 and / or the secondary winding 8, making the entire magnetic integrated transformer more compact and the wiring simpler and more convenient.

[0035] In some embodiments, the primary winding 7 passes through the escapement 30 .

[0036] In some embodiments, the secondary winding 8 passes through the escapement 30 .

[0037] In some embodiments, both the primary winding 7 and the secondary winding 8 pass through the escape portion 30 .

[0038] In some embodiments, the avoidance portion 30 may not be provided, but a hole or a groove may be opened on the core center column 3 for the primary winding 7 and / or the secondary winding 8 to pass through.

[0039] See also Figure 3 The outer surface of the primary winding 7 is provided with a coating 9 .

[0040] In some embodiments, a coating 9 is provided on the outer surface of the secondary winding 8 .

[0041] In some embodiments, outer surfaces of the primary winding 7 and the secondary winding 8 are provided with a coating 9 .

[0042] The coating 9 is wound outside the primary winding 7 and / or the secondary winding 8, which can make the winding arrangement structure more orderly and effectively reduce the projection area of ​​the magnetic component.

[0043] In this embodiment, the coating 9 is a square coating, and the coating 9 is wound outside the winding wire, so that the winding arrangement is more neat and consistent, the gap and space waste are reduced, and the space utilization rate in the magnetic integrated transformer is improved.

[0044] In some embodiments, the coating 9 may be made of copper foil, aluminum foil, enameled square copper wire, or the like.

[0045] In some implementations, the coating 9 may not be provided, and flat primary windings 7 and secondary windings 8 may be used for winding.

[0046] See also Figure 3 and Figure 4As shown, the primary winding 7 includes a first primary winding 71, and the secondary winding 8 includes a first secondary winding 81. The first primary winding 71 and the first secondary winding 81 are wound around the first magnetic core side column 41. The first primary winding 71 and the first secondary winding 81 are stacked along a first direction. Winding the first primary winding 71 and the first secondary winding 81 around the first magnetic core side column 41 can enhance the magnetic coupling between the first primary winding 71 and the first secondary winding 81, thereby improving the transmission efficiency of the magnetic integrated transformer.

[0047] In some embodiments, the first primary winding 71 is wound outside the first secondary winding 81 .

[0048] In some embodiments, the first secondary winding 81 is wound outside the first primary winding 71 .

[0049] The primary winding 7 includes a second primary winding 72, and the secondary winding 8 includes a second secondary winding 82. The second primary winding 72 and the second secondary winding 82 are wound around the second magnetic core side column 42. One of the second primary winding 72 and the second secondary winding 82 is wound around the outside of the other, which can enhance the magnetic coupling between the second primary winding 72 and the second secondary winding 82 and improve the transmission efficiency of the magnetic integrated transformer.

[0050] In some embodiments, the second primary winding 72 is wound outside the second secondary winding 82 .

[0051] In some embodiments, the second secondary winding 82 is wound outside the second primary winding 72 .

[0052] In some embodiments, the second primary winding 72 and the second secondary winding 82 are overlapped along the first direction.

[0053] In some embodiments, the second secondary winding 82 and the second primary winding 72 are arranged to overlap along the first direction.

[0054] The first primary winding 71 is connected in series with the second primary winding 72 , and the first secondary winding 81 is connected in series with the second secondary winding 82 .

[0055] In some embodiments, a connection portion between the first primary winding 71 and the second primary winding 72 passes through the avoidance portion 30 .

[0056] In some embodiments, a connection portion between the first secondary winding 81 and the second secondary winding 82 passes through the avoidance portion 30 .

[0057] In some embodiments, the first primary winding 71 and the second primary winding 72 are wound by one complete winding wire.

[0058] In some embodiments, the first secondary winding 81 and the second secondary winding 82 are wound by one complete winding wire.

[0059] In some embodiments, the first primary winding 71 is first wound six times on the first magnetic core side column 41, and the second secondary winding 82 is wound five times on the second magnetic core side column 42, and then the first secondary winding 81 is wound two times on the outside of the first primary winding 71, and the second primary winding 72 is wound three times on the outside of the second secondary winding 82. At this time, the turns ratio of the primary winding 7 and the secondary winding 8 is 9:7, the number of winding turns on the first magnetic core side column 41 is the same as the number of winding turns on the second magnetic core side column 42, and the present application does not limit the turns ratio of the primary winding 7 and the secondary winding 8.

[0060] In some embodiments, the difference between the total number of winding turns on the first magnetic core side column 41 and the total number of winding turns on the second magnetic core side column 42 is less than or equal to three turns.

[0061] See also Figure 4 and Figure 5 As shown, the core column 3 includes: an upper core column 31 and a lower core column 32 stacked along a first direction, the upper core column 31 is fixed to the upper core 1, the lower core column 32 is fixed to the lower core 2, and a first air gap 5 is provided between the upper core column 31 and the lower core column 32, and the first air gap 5 is used to control the excitation inductance of the magnetic integrated transformer.

[0062] In some implementations, the width of the first air gap 5 can be adjusted by grinding the upper magnetic core center column 31 and the lower magnetic core center column 32 .

[0063] In some embodiments, the width of the first air gap 5 is adjusted by padding the first air gap 5 with epoxy sheets, DuPont paper, etc.

[0064] In some embodiments, epoxy sheets and magnetic sheets may be placed in the first air gap 5. The magnetic sheets are made of the same material as the upper magnetic core 1 and the lower magnetic core 2. The epoxy sheets and the magnetic sheets are spaced apart to divide the first air gap 5 into several small sections, thereby reducing eddy current losses.

[0065] The first magnetic core side column 41 includes: a first upper magnetic core side column 411 and a first lower magnetic core side column 412 stacked along a first direction, the first upper magnetic core side column 411 is fixed to the upper magnetic core 1, the first lower magnetic core side column 412 is fixed to the lower magnetic core 2, and a second air gap 6 is provided between the first upper magnetic core side column 411 and the first lower magnetic core side column 412, and the second air gap 6 is used to control the leakage inductance of the magnetic integrated transformer.

[0066] The second magnetic core side column 42 includes: a second upper magnetic core side column 421 and a second lower magnetic core side column 422 stacked along the first direction, the second upper magnetic core side column 421 is fixed to the upper magnetic core 1, the second lower magnetic core side column 422 is fixed to the lower magnetic core 2, and a second air gap 6 is provided between the second upper magnetic core side column 421 and the second lower magnetic core side column 422.

[0067] In some implementations, the leakage inductance of the transformer is adjusted by adjusting the width of the second air gap 6 so that the leakage inductance of the transformer is equal to the required leakage inductance, and the required leakage inductance is the required inductance of the resonant inductor, thereby realizing the integration of the resonant inductor and the transformer.

[0068] In some embodiments, the width of the second air gap 6 is adjusted by padding the second air gap 6 with an epoxy sheet, DuPont paper, or the like.

[0069] In some embodiments, epoxy sheets and magnetic sheets may be placed in the second air gap 6. The magnetic sheets are made of the same material as the upper magnetic core 1 and the lower magnetic core 2. The epoxy sheets and the magnetic sheets are spaced apart to divide the second air gap 6 into several small sections, thereby reducing eddy current losses.

[0070] In some embodiments, the width of the second air gap 6 can be adjusted by mechanical adjustment such as bolts, wedges, etc.

[0071] In some implementations, the width of the second air gap 6 can be adjusted by grinding the first upper magnetic core side column 411 and the first lower magnetic core side column 412 .

[0072] In some implementations, the width of the second air gap 6 can be adjusted by grinding the second upper magnetic core side column 421 and the second lower magnetic core side column 422 .

[0073] See also Figure 5 As shown, along the first direction, the height of the first air gap 5 is greater than the height of the second air gap 6. The larger first air gap 5 can better guide the magnetic flux and improve the overall magnetic flux utilization rate.

[0074] In some embodiments, along the first direction, the height of the first air gap 5 may also be less than or equal to the height of the second air gap 6 .

Claims

1. A magnetic integrated transformer, characterized in that: include: An upper magnetic core, a lower magnetic core, a primary winding, a secondary winding, a magnetic core center column, a first magnetic core side column and a second magnetic core side column, wherein the upper magnetic core and the lower magnetic core are stacked along a first direction, the magnetic core center column, the first magnetic core side column and the second magnetic core side column are located between the upper magnetic core and the lower magnetic core, and along a second direction perpendicular to the first direction, the magnetic core center column is located between the first magnetic core side column and the second magnetic core side column, and after the magnetic core center column, the first magnetic core side column and the second magnetic core side column are cut along the second direction, the cross-sectional area of ​​the magnetic core center column is defined as S1, the cross-sectional area of ​​the first magnetic core side column is defined as S2, and the cross-sectional area of ​​the second magnetic core side column is defined as S3, S1 is greater than or equal to 2 times S2 and 2 times S3, and one of the primary winding and the secondary winding is wrapped around the first magnetic core side column, and the other is wrapped around the second magnetic core side column.

2. The magnetic integrated transformer according to claim 1, characterized in that: One end of the middle column of the magnetic core is retracted relative to the edge of the lower magnetic core to form an escape portion for the primary winding and / or the secondary winding to pass through.

3. The magnetic integrated transformer according to claim 1, characterized in that: The primary winding includes a first primary winding, and the secondary winding includes a first secondary winding. The first primary winding and the first secondary winding are wound around the first magnetic core side column, and the first primary winding and the first secondary winding are overlapped along the first direction.

4. The magnetic integrated transformer according to claim 3, characterized in that: The primary winding includes a second primary winding, and the secondary winding includes a second secondary winding. The second primary winding and the second secondary winding are wound around the second magnetic core side column, and one of the second primary winding and the second secondary winding is wound around the outside of the other.

5. The magnetic integrated transformer according to claim 4, characterized in that: The first primary winding is connected in series with the second primary winding, and the first secondary winding is connected in series with the second secondary winding.

6. The magnetic integrated transformer according to claim 1, characterized in that: The outer surface of the primary winding and / or the secondary winding is provided with a coating.

7. The magnetic integrated transformer according to any one of claims 1 to 6, characterized in that: The magnetic core center column comprises: an upper magnetic core center column and a lower magnetic core center column stacked along the first direction, the upper magnetic core center column and the upper magnetic core are fixed, the lower magnetic core center column and the lower magnetic core are fixed, and a first air gap is provided between the upper magnetic core center column and the lower magnetic core center column.

8. The magnetic integrated transformer according to claim 7, characterized in that: The first magnetic core side column includes: a first upper magnetic core side column and a first lower magnetic core side column stacked along the first direction, the first upper magnetic core side column and the upper magnetic core are fixed, the first lower magnetic core side column and the lower magnetic core are fixed, and a second air gap is provided between the first upper magnetic core side column and the first lower magnetic core side column.

9. The magnetic integrated transformer according to claim 8, characterized in that: The second magnetic core side column includes: a second upper magnetic core side column and a second lower magnetic core side column stacked along the first direction, the second upper magnetic core side column and the upper magnetic core are fixed, the second lower magnetic core side column and the lower magnetic core are fixed, and a second air gap is provided between the second upper magnetic core side column and the second lower magnetic core side column.

10. The magnetic integrated transformer according to claim 9, characterized in that: Along the first direction, a height of the first air gap is greater than a height of the second air gap.

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