Transformer

Abstract

The utility model relates to a transformer which comprises a shell, a primary winding, a secondary winding and a magnetic core, and the primary winding, the secondary winding and the magnetic core are installed in the shell. The wire inlet end of the primary winding and the wire outlet end of the secondary winding are arranged in a wire outlet insulating column on the shell; wherein the primary winding and the secondary winding are wound on an inner layer and an outer layer of the same magnetic core, an insulating material is filled between the primary winding and the secondary winding, and the primary winding and the secondary winding are wrapped in an insulating material structure; the magnetic core is connected with the shell through a mounting frame, the mounting frame is connected with the magnetic core and the shell through bolts, and an insulating material is filled between the shell and the magnetic core; two insulating columns are arranged on the shell, and the wire inlet end and the wire outlet end are arranged in the two insulating columns respectively. The charging pile transformer solves the technical problems that a charging pile transformer in the prior art is large in size and low in performance and installation efficiency.

Description

Technical Field

[0001] The present application belongs to the technical field of inductor component design, and in particular, relates to a transformer. Background Art

[0002] With the rapid expansion of the electric vehicle market, charging piles are key facilities for the energy supply of electric vehicles, and it is particularly important to improve their performance and efficiency. In the composition of charging piles, transformers play a vital role, responsible for the conversion of DC to DC, which is directly related to the overall efficiency of charging piles. At present, most transformers adopt industrial frequency design, which leads to the problems of large transformer size and low efficiency, and it is difficult to meet the needs of modern electric vehicles for high efficiency and fast charging. Therefore, the development of a smaller and more efficient high-frequency transformer is of great significance to improve the performance and efficiency of charging piles. Utility Model Content

[0003] In view of the deficiencies existing in the related technologies, the utility model provides a transformer to solve the technical problems of large size, low performance and installation efficiency of the existing charging pile transformer.

[0004] According to the first aspect of the present application, a transformer is provided. In a possible implementation, the transformer includes: a shell, a primary winding, a secondary winding and a magnetic core, wherein the primary winding, the secondary winding and the magnetic core are installed in the shell; the incoming line end of the primary winding and the outgoing line end of the secondary winding are installed in insulating columns on the shell; wherein the primary winding and the secondary winding are wound around the inner and outer layers of the same magnetic core, insulating material is filled between the primary winding and the secondary winding, and the primary winding and the secondary winding are wrapped in an insulating material structure; the magnetic core is connected to the shell by a mounting frame, the mounting frame is connected to the magnetic core and the shell by bolts, and insulating material is filled between the shell and the magnetic core; two insulating columns are arranged on the shell, and the incoming line end and the outgoing line end are respectively arranged in the two insulating columns.

[0005] In a possible implementation manner, the primary winding and the secondary winding are respectively wound crosswise, and the second layer of coils is wound on the first layer of coils after the first layer of coils are wound, and the input end and the output end of the coils are on the same side.

[0006] In a possible implementation, the magnetic core is made of amorphous nanocrystalline alloy.

[0007] In a possible implementation manner, the primary winding and the secondary winding use Litz wire.

[0008] In a possible implementation, the housing is an aluminum alloy housing.

[0009] In a possible implementation manner, the insulating material is epoxy resin.

[0010] In a possible implementation manner, the magnetic core outside the portion wrapped by the insulating material is wrapped with a stainless steel shell; and the mounting frame is connected to the stainless steel shell by bolts.

[0011] In a possible implementation, the housing further includes a detachable cover plate, the insulating column is mounted on the cover plate, two insulating holes are arranged in the insulating column, and two lead wires of the outlet or the inlet pass through the two insulating holes.

[0012] Based on the above technical scheme, in the transformer of the embodiment of the utility model, the primary winding and the secondary winding are concentrically wound, which reduces the volume of the transformer and makes the application scope wider; the magnetic core and the shell are connected by a mounting frame and fixed by bolts, which not only enhances the stability of the structure during the potting glue, but also makes the overall structure more solid, compact and small, easy to install, and convenient for maintenance and repair; the two insulating column design on the shell effectively isolates the incoming line end and the outgoing line end, further improving the safety during use. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of the present application. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation on the present invention. In the drawings:

[0014] Figure 1 This is a schematic cross-sectional structure diagram of a transformer according to one embodiment of the utility model;

[0015] Figure 2 This is a schematic diagram of electrical connections of a transformer according to one embodiment of the utility model;

[0016] Figure 3 This is a schematic diagram of the appearance structure of a transformer according to one embodiment of the utility model;

[0017] Figure 4 This is a schematic diagram of the exploded structure of a transformer according to one embodiment of the utility model;

[0018] Figure 5 This is a schematic structural diagram of the installation of an iron core and a coil inside a transformer shell according to one embodiment of the utility model.

[0019] In the figure:

[0020] 1. Outlet terminal; 2. Shell; 3. Magnetic core; 4. Insulation material structure; 5. Inlet terminal; 6. Secondary winding; 7. Primary winding; 9. Cover plate; 10. Stainless steel shell; 11. Mounting frame; 13. Bolts; 14. Insulation column. DETAILED DESCRIPTION

[0021] The following will be combined with the drawings in the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments of the present application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

[0022] In the description of the present application, it should be understood that the terms "center", "lateral", "longitudinal", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present application.

[0023] The terms "first", "second", and "third" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the technical features indicated. Thus, a feature defined as "first", "second", and "third" may explicitly or implicitly include one or more of the features.

[0024] In the description of this application, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a direct connection, or an indirect connection through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0025] In order to solve the technical problems in the prior art that the charging pile transformer is large in size, low in performance and installation efficiency, the present application provides a transformer.

[0026] See also Figure 1 , Figure 3 , Figure 4 and Figure 5In a possible implementation, the transformer includes: a shell 2, a primary winding 7, a secondary winding 6 and a magnetic core 3, wherein the primary winding 7, the secondary winding 6 and the magnetic core 3 are installed in the shell 2; the incoming line terminal 5 of the primary winding 7 and the outgoing line terminal 1 of the secondary winding 6 are installed in the outgoing line insulating column 14 on the shell 2; wherein the primary winding 7 and the secondary winding 6 are wound around the inner and outer layers of the same magnetic core 3, the primary winding 7 and the secondary winding 6 are filled with insulating material, and the primary winding 7 and the secondary winding 6 are wrapped in an insulating material structure 4; the magnetic core 3 is connected to the shell 2 through a mounting frame 11, the mounting frame 11 is connected to the magnetic core 3 and the shell 2 through bolts 13, and the shell 2 and the magnetic core 3 are filled with insulating material; two insulating columns 14 are arranged on the shell 2, and the incoming line terminal 5 and the outgoing line terminal 1 are respectively arranged in the two insulating columns 14.

[0027] In the above scheme, electromagnetic compatibility and safety are taken into consideration in the structural design of the transformer. The high efficiency and long-term stable operation of the transformer are ensured through the precise layout of the internal components, the winding method of the primary winding and the secondary winding, the connection method of the magnetic core and the shell, and the application of insulating materials. In this embodiment, the magnetic core and the shell are connected by a mounting frame, which not only enhances the stability of the structure, but also is fixed by bolts, making the overall structure more solid and easy to maintain and overhaul. The two insulating column designs on the shell effectively isolate the incoming and outgoing terminals, further improving the safety during use.

[0028] See also Figure 2 , electrical connection diagram of the transformer, the incoming terminal 5 on the primary winding 7 side serves as the voltage input terminal of the transformer, and the outgoing terminal 1 on the secondary winding 6 side serves as the voltage output terminal of the transformer. The voltage is input at the incoming terminal 5, and the voltage value required by the design is output at the outgoing terminal 1 through mutual inductance.

[0029] In a possible implementation manner, the primary winding 7 and the secondary winding 6 are respectively wound crosswise, and the second layer of coils is wound on the first layer of coils after the first layer of coils are wound, and the input end and the output end of the coils are on the same side.

[0030] In the above scheme, the cross-winding winding method not only improves the uniformity of the transformer's magnetic field and reduces energy loss, but also optimizes the space utilization of the transformer. This design enables the transformer to be more efficient when transmitting electrical energy and the heat distribution is more uniform, thereby extending the service life of the transformer. By setting the input and output ends of the coil on the same side, the wiring of the transformer is simplified, making it easier to install and maintain.

[0031] In a possible implementation, the material of the magnetic core 3 is an amorphous nanocrystalline alloy.

[0032] In the above scheme, amorphous nanocrystalline alloy is used as the core material, which has excellent magnetic properties and low loss. The use of this material significantly improves the efficiency of the transformer and reduces energy consumption. Amorphous nanocrystalline alloy has high saturation magnetic induction intensity and good anti-magnetic saturation ability, so that the transformer can still maintain stable performance under high load and is suitable for use in a variety of working environments.

[0033] In a possible implementation, the primary winding 7 and the secondary winding 6 are made of Litz wire.

[0034] In the above scheme, the use of Litz wire further improves the electrical performance of the transformer. Due to its unique structure, Litz wire can effectively reduce the skin effect and proximity effect, thereby reducing the resistance loss at high frequency. This makes the transformer perform better in high-frequency applications, with better transmission efficiency and lower heat loss. The application of Litz wire, together with the aforementioned amorphous nanocrystalline alloy core, constitutes a high-efficiency, low-loss transformer design.

[0035] In a possible implementation, the housing 2 is an aluminum alloy housing.

[0036] In the above scheme, aluminum alloy is selected as the shell, not only because of its good thermal conductivity, which helps to quickly dissipate the heat inside the transformer, but also because aluminum alloy has a light weight, which is convenient for the transportation and installation of the transformer. In addition, the aluminum alloy shell also has strong corrosion resistance and mechanical strength, which can protect the internal components of the transformer under various environmental conditions and extend the service life of the transformer.

[0037] In a possible implementation manner, the insulating material structure 4 is made of epoxy resin.

[0038] In the above scheme, epoxy resin is selected as the insulating material structure 4, which provides excellent electrical insulation performance and chemical stability. Epoxy resin can not only effectively isolate electrical components and prevent electrical failures, but also has good bonding properties, which can enhance the integrity and sealing of the internal structure of the transformer. In addition, the application of epoxy resin also helps to prevent moisture and dust, further improving the reliability and durability of the transformer.

[0039] In a possible implementation manner, the magnetic core 3 outside the portion wrapped by the insulating material structure 4 is wrapped by a stainless steel shell 10 ; the mounting frame 11 is connected to the stainless steel shell 10 by bolts 13 .

[0040] In the above scheme, the stainless steel shell design outside the magnetic core not only provides additional mechanical protection and ensures the stable operation of the transformer in harsh environments, but the selection of stainless steel materials further enhances the corrosion resistance and durability of the transformer. The connection method of bolts and mounting brackets makes the installation and maintenance of the transformer more convenient, improving the maintainability and reliability of the transformer.

[0041] In a possible implementation, the housing 2 further includes a detachable cover plate 9, an insulating column 14 is mounted on the cover plate 9, two insulating holes are provided in the insulating column 14, and two lead wires of the outlet terminal 1 or the inlet terminal 5 pass through the two insulating holes.

[0042] In the above scheme, the design of the detachable cover provides great convenience for the inspection and maintenance of the transformer; by setting insulating holes on the insulating columns and allowing the lead wires to pass through, it not only optimizes the layout of the wires and reduces the interference between the wires, but also enhances the safety of the transformer. This design takes into account the convenience and practicality of the transformer during use, so that the transformer can provide stable and reliable performance in different application environments.

[0043] The transformer of the embodiment of the present application can be used in an electric vehicle charging pile. The high-frequency transformer achieves an efficient and compact design by optimizing the magnetic core material, coil structure and cooling method.

[0044] The high-frequency transformer for charging piles of the above scheme includes a primary winding and a secondary winding, as well as a magnetic core and an aluminum alloy shell, and a structure of an outlet insulating column is provided on the outside of the shell; wherein the main material of the winding is Litz wire, which is wound in a cross-winding manner, and the magnetic core structure is made of amorphous nanocrystalline alloy, which has good high-frequency response characteristics and low magnetic loss, thereby improving the working efficiency of the transformer; the primary winding and the secondary winding are wound on one side of the magnetic core in a cross-winding manner with two wires in parallel, and are electrically isolated by insulating materials, thereby improving the power density and product safety of the product; the structural design of the transformer is optimized, the volume and weight are reduced, and installation and use are convenient; at the same time, the wire package wound on the magnetic core is fixed on the aluminum alloy shell and cast together with epoxy resin, thereby strengthening the mechanical structure performance of the product, and facilitating the stable operation and heat dissipation of the product; wherein the amorphous nanocrystalline iron core is wrapped in a stainless steel shell, and a detachable fixing part, i.e., a mounting frame, is added to the outside of the shell, which is conducive to fixing the iron core in the aluminum alloy shell, reducing the influence of uncertain factors on the fixing of the iron core wire package and the shell, and helping to improve the assembly efficiency of the product.

[0045] The magnetic core structure of the present application greatly improves the efficiency of the transformer at high frequencies, reduces energy waste, and also improves the safety of charging; the design of electrical isolation and epoxy resin casting effectively prevents the risk of electric shock to users and improves the safety of the product.

[0046] Finally, it should be noted that: the various embodiments in this specification are described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the various embodiments can be referenced to each other.

[0047] The above embodiments are only used to illustrate the technical solution of the present application rather than to limit it. Although the present application has been described in detail with reference to the preferred embodiments, ordinary technicians in the relevant field should understand that the specific implementation methods of the present application can still be modified or some technical features can be replaced by equivalents without departing from the spirit of the technical solution of the present application, which should be included in the scope of the technical solution requested for protection in the present application.

Claims

1. A transformer, characterized in that: include: A housing (2), a primary winding (7), a secondary winding (6) and a magnetic core (3), wherein the primary winding (7), the secondary winding (6) and the magnetic core (3) are installed in the housing (2); an inlet terminal (5) of the primary winding (7) and an outlet terminal (1) of the secondary winding (6) are installed in an insulating column (14) on the housing (2); The primary winding (7) and the secondary winding (6) are wound on the inner and outer layers of the same magnetic core (3), an insulating material is filled between the primary winding (7) and the secondary winding (6), and the primary winding (7) and the secondary winding (6) are wrapped in the insulating material structure (4); The magnetic core (3) and the outer shell (2) are connected via a mounting frame (11), the mounting frame (11) is connected to the magnetic core (3) and the outer shell (2) via bolts (13), and an insulating material is filled between the outer shell (2) and the magnetic core (3); Two insulating columns (14) are arranged on the housing (2), and the incoming line terminal (5) and the outgoing line terminal (1) are arranged in the two insulating columns (14) respectively.

2. The transformer according to claim 1, characterized in that: The primary winding (7) and the secondary winding (6) are respectively wound crosswise, and the second layer of coils is wound on the first layer of coils after the first layer of coils are wound, and the input end and the output end of the coils are on the same side.

3. The transformer according to claim 2, characterized in that: The material of the magnetic core (3) is an amorphous nanocrystalline alloy.

4. The transformer according to claim 3, characterized in that: The primary winding (7) and the secondary winding (6) use Litz wire.

5. The transformer according to claim 4, characterized in that: The housing (2) is an aluminum alloy housing.

6. The transformer according to claim 5, characterized in that: The insulating material structure (4) is made of epoxy resin.

7. The transformer according to claim 6, characterized in that: The magnetic core (3) outside the portion wrapped by the insulating material is wrapped with a stainless steel shell (10); the mounting frame (11) is connected to the stainless steel shell (10) via bolts (13).

8. The transformer according to claim 7, characterized in that: The housing (2) also includes a detachable cover plate (9), an insulating column (14) is mounted on the cover plate (9), two insulating holes are arranged in the insulating column (14), and two lead wires of the outlet terminal (1) and the inlet terminal (5) pass through the two insulating holes.

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