Main transformer module of rectifying device
By designing the secondary winding of the inner and outer double-layer structures and the shell and rear cover of conductive material in the main transformer module, the problems of large thermal resistance and low power of the existing main transformer module are solved, and more efficient heat dissipation and higher power output are achieved.
Patent Information
- Application Number
- CN202421211674.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-05-29
- Publication Date
- 2025-03-14
- Estimated Expiration
- 2034-05-29
AI Technical Summary
Due to the large structural thermal resistance and low thermal conductivity of the potting material, the existing main transformer modules have low power at the same volume. In high power applications, the core is easily saturated or damaged by high temperature, which affects the reliability and electrical parameters of the equipment.
The main transformer module design adopts the rectifier device, in which the secondary winding consists of several conductive bodies, forms an inner and outer double-layer structure, expands the heat dissipation area, and is set as a conductive material through the shell and the rear cover, shortens the heat dissipation and circuit paths, and improves heat dissipation and power transfer efficiency.
It significantly improves the heat dissipation efficiency, increases the main change power by at least 50%, and reduces costs, improving the reliability of the equipment and the stability of the electrical parameters.
Smart Images
Figure CN222619516U_ABST
Abstract
Description
Technical Field
[0001] The utility model belongs to the technical field of high-frequency rectifiers, in particular to a main transformer module of a rectifier device. Background Art
[0002] The main transformer (referred to as the main transformer) is a key component of the high-frequency rectifier. Since the thermal conductive main transformer does not need to be equipped with cooling pipes for heat dissipation, the production process is simple, there is no risk of leakage or blockage, and the number of internal pipe interfaces of the equipment can be reduced, it is widely used in liquid-cooled high-frequency rectifiers. Most thermal conductive main transformers are wound with a ring-shaped magnetic core, and then potted with a thermal conductive potting aluminum box and installed on a liquid-cooled radiator. The heat generated during operation is transferred to the thermal conductive potting aluminum box through the potting material, and finally the heat is transferred to the liquid-cooled radiator and taken away by the coolant. Limited by the factors of large thermal resistance of the original structure and generally low thermal conductivity of the potting material, the power of the thermal conductive main transformer is generally low under the same volume. When applied to high-power specifications, especially those with large current and low voltage, it can only be processed by increasing the number of magnetic cores, increasing the volume of the main transformer, increasing the cross-sectional area of the winding copper material, and using potting materials with higher thermal conductivity, resulting in a large increase in the cost of the thermal conductive main transformer. Otherwise, excessive temperature will cause saturation of the magnetic core, or the high temperature will damage the inter-turn insulation layer of the original side line and cause a short circuit, which will eventually have a serious impact on the reliability and electrical parameters of the equipment.
[0003] In summary, the existing main transformer module has low power at the same volume due to its large structural thermal resistance and low thermal conductivity of the potting material. In high-power applications, performance needs to be improved by increasing the magnetic core, increasing the volume, and using high thermal conductivity potting materials, but this will greatly increase costs. Otherwise, high temperature may cause the magnetic core to saturate or damage the inter-turn insulation layer, affecting the reliability and electrical parameters of the equipment. Utility Model Content
[0004] The utility model aims to overcome the deficiencies of the prior art and provide a main transformer module capable of improving heat dissipation efficiency.
[0005] In order to solve the above technical problems, the utility model adopts the following technical solutions:
[0006] The main transformer module of the rectifier device includes a shell made of heat-conducting material, a rear cover, a transformer module and a heat sink, wherein the shell is provided with a accommodating cavity penetrating the rear end thereof, and the rear cover closes the accommodating cavity opening at the rear end of the shell; the transformer module is arranged in the accommodating cavity, and includes an annular magnetic core, a primary wire package and a secondary winding, wherein the annular magnetic core is fixed on the rear cover, the primary wire package is wound on the annular magnetic core, and the secondary winding includes a plurality of conductors, which are wound on the front end and two side surfaces of the primary wire package in a three-sided covering manner, and the gaps between the annular magnetic core, the primary wire package, the secondary winding and the inner wall of the accommodating cavity are filled with insulating heat-conductive potting materials; the heat sink is arranged on the outside of the shell.
[0007] Compared with the prior art, the secondary winding of the main transformer module of the utility model is composed of a plurality of conductors wound on the outside of the primary wire package, and forms an inner and outer double-layer structure with the primary wire package on the annular magnetic core. The secondary winding covers the inner side, outer side and front end of the primary wire package, thereby expanding the heat dissipation area. The heat of the primary wire package and the annular magnetic core can be transferred to the conductor through three surfaces, and the conductor then transfers the heat to the shell through the outer side. In addition, since the annular magnetic core is fixed on the rear cover plate, and the rear cover plate and the shell are integrated, the heat of the annular magnetic core and the primary wire package is also transferred to the shell through the rear end surface of the primary wire package, thereby forming a heat dissipation structure with two ends and five surfaces. Due to the increase in the overall heat dissipation area and the reduction in thermal resistance, the heat dissipation effect is significantly improved, and the power of the main transformer can be increased by at least 50%. It should be noted that the two ends and five surfaces of the utility model refer to the front and rear ends of the transformer module and the inner and outer annular surfaces of the annular secondary winding, as well as the surface where the primary wire package overlaps with the rear cover plate.
[0008] Furthermore, the shell and the rear cover are made of conductive materials, and the rear cover is provided with an outlet portion, one of the electrodes of the secondary winding is connected to the rear cover, and the other electrode is connected to the external circuit system through the outlet portion. In this solution, the shell and the rear cover are made of conductive materials, so that one of the electrodes of the secondary winding can be directly connected to the rear cover, so that the rear cover and the shell are used as electrode connection ends. On the one hand, the heat dissipation and conduction paths can be shortened, and the heat dissipation and power transmission efficiency can be improved. On the other hand, there is no need to perform insulation treatment between the rear cover and the shell, making its processing method simpler. In practical applications, the shell and the rear cover can be used as negative electrodes, one of the electrodes of the secondary winding is connected to the rear cover, and the other electrode is connected to the positive electrode of the circuit through the outlet portion, such as connected to the electrode connection plate of the positive electrode. It should be noted that "connected to an external circuit system" in this solution can be understood as but not limited to direct connection or indirect connection through an electrode connection plate.
[0009] Furthermore, the conductor is U-shaped, one end of the U-shaped conductor is connected to the rear cover as one of the electrodes, and the other end passes through the outlet portion. In this solution, the shape of the conductor matches the original edge wire package, and the two ends of the U-shaped opening are used as the positive electrode and the negative electrode respectively, thereby achieving a compact and efficient circuit design.
[0010] Furthermore, the secondary winding is provided with at least two groups, which are evenly distributed with the center of the annular magnetic core as the symmetric center, and three adjacent conductors are arranged in a "pin" shape near the inner circle of the annular magnetic core. Through the arrangement of this scheme, more conductors can be wound around the surface of the primary wire package, so that the surface of the primary wire package is fully and evenly covered. Such a design can avoid the local surface of the primary wire package being exposed, thereby solving the problem of slow local heat dissipation and heat accumulation.
[0011] Furthermore, the cross section of the accommodating cavity is set to be circular to match the transformer module, and the inner wall of the accommodating cavity is provided with tooth grooves to match the outer contour of the conductor. This solution greatly reduces the thermal resistance of the primary winding and the secondary winding to the shell, and increases the heat dissipation area between the two, thereby improving the heat dissipation effect of the shell side.
[0012] Furthermore, the accommodating cavity runs through the front end of the shell, the radiator includes a first radiator, the first radiator is arranged at the front end of the shell and closes the opening of the accommodating cavity at the front end of the shell, and there is a gap of a preset distance between the front end of the secondary winding and the first radiator. In this solution, the radiator and the shell are set as one body, which can shorten the heat dissipation path and improve the heat dissipation performance.
[0013] Furthermore, the gap is filled with a thermally conductive gasket, the thermally conductive gasket is made of a flexible material, and the preset distance is less than the thickness of the thermally conductive gasket. In this solution, since the thickness of the thermally conductive gasket is greater than the preset gap, after assembly, the conductor will be partially squeezed and embedded in the thermally conductive gasket, thereby increasing the contact area between the two, expanding the heat dissipation area, and at the same time, reducing the thermal resistance from the front end of the transformer module to the first heat sink.
[0014] Furthermore, the radiator includes a second radiator, which is arranged on the rear side of the rear cover plate and is insulated from the rear cover plate. In this solution, radiators are arranged at both the front and rear ends of the shell, and the shell can dissipate heat synchronously through the front and rear ends, thereby improving the heat dissipation performance, thereby ensuring the stable operation of the main transformer module and extending its service life.
[0015] Furthermore, it also includes an electrode connection plate, which is arranged on the rear side of the rear cover plate, and one of the electrodes of the secondary winding is connected to the electrode connection plate and is insulated and connected to the second heat sink. In this solution, the electrode connection plate is arranged on the rear side of the rear cover plate, so that the other electrode of the conductor passes through the outlet portion and is uniformly collected to the electrode connection plate, so that one of the electrodes of the secondary winding is connected to the external circuit system through the electrode connection plate.
[0016] Furthermore, the electrode connecting plate and the second heat sink are connected by a heat conducting block, and an insulating layer is provided on at least one of the butt joint surfaces of the electrode connecting plate and the second heat sink. BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Figure 1 This is the overall schematic diagram of the main transformer module;
[0018] Figure 2 Structural decomposition of the main transformer module Figure 1 ;
[0019] Figure 3 Structural decomposition of the main transformer module Figure 2 ;
[0020] Figure 4 is a cross-sectional view of the housing and the transformer module;
[0021] Figure 5 Disassembly of the housing and transformer module Figure 2 ;
[0022] Figure 6 This is the assembly drawing of the housing and transformer module.
[0023] Description of labels:
[0024] The first radiator 1, the second radiator 5, the main transformer module 7, the rear cover plate 71, the first outlet portion 711, the second outlet portion 712, the first wiring hole 713, the second wiring hole 714, the electrode connecting plate 72, the heat conductive block 73, the shell 8, the accommodating cavity 80, the tooth groove 81, the inner ring heat conductive block 82, the air avoidance portion 83, the transformer module 9, the primary side wire package 91, the secondary side winding 92, the first winding 921, the second winding 922, the conductor 911, and the magnetic core 93. DETAILED DESCRIPTION
[0025] A preferred specific implementation of the present utility model is described below in conjunction with the accompanying drawings.
[0026] In the description of the present invention, it is necessary to understand that the directions or positional relationships indicated by “up”, “down”, “left”, “right”, “front”, “back”, “inside” and “outside”, etc., are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as a limitation on the present invention.
[0027] See also Figure 1-6 As shown, the utility model discloses a main transformer module 7 of a rectifier device, which includes a shell 8 made of heat-conducting material, a rear cover plate 71, a transformer module 9 and a heat sink. The shell 8 is provided with a housing chamber 80 that runs through its rear end, and the rear cover plate 71 closes the rear end opening of the housing chamber 80; the transformer module 9 is arranged in the housing chamber 80, and includes an annular magnetic core 93, a primary wire package 91 and a secondary winding 92. The annular magnetic core 93 is fixed on the rear cover plate 71, and the primary wire package 91 is wound on the annular magnetic core 93. The secondary winding includes a plurality of conductors 911, and the conductors 911 are wound on the front end and two side surfaces of the primary wire package 91 in a three-sided covering manner. The annular magnetic core 93, the primary wire package 91, the secondary winding 92 and the inner wall of the housing chamber 80 are isolated by insulating and heat-conducting materials; the heat sink is arranged on the outside of the shell 8.
[0028] The shell 8 and the rear cover 71 are made of conductive materials. The rear cover 71 is provided with an outlet. One of the electrodes of the secondary winding 92 is connected to the rear cover 71, and the other electrode is connected to the external circuit system through the outlet. In this solution, the shell 8 and the rear cover 71 are made of conductive materials so that one of the electrodes of the secondary winding 92 can be directly connected to the rear cover 71, so that the rear cover 71 and the shell 8 are used as electrode connection ends. On the one hand, the heat dissipation and conductive paths can be shortened, and the heat dissipation and power transmission efficiency can be improved. On the other hand, there is no need to perform insulation treatment between the rear cover 71 and the shell 8, making its processing method simpler. In practical applications, the shell 8 and the rear cover 71 can be used as negative electrodes.
[0029] The specific structural scheme of the above-mentioned conductor 911 is as follows: the whole is U-shaped, one end of the U-shaped is connected to the rear cover plate 71 as one of the electrodes, and the other end passes through the outlet portion. This arrangement makes the shape of the conductor 911 fit the original edge wire package 91, and the two ends of the U-shaped opening are used as the positive electrode and the negative electrode respectively, thereby realizing a compact and efficient circuit design.
[0030] The secondary winding 92 is provided with at least two groups, which are evenly distributed with the center of the annular magnetic core 93 as the symmetric center. Among them, three adjacent conductors 911 are arranged in a "pin" shape near the inner circle of the annular magnetic core. Such a design allows us to place the middle conductor 911 closer to the rotation center, so that more conductors 911 can be wound around the surface of the primary wire package 91, achieving comprehensive and uniform coverage, effectively preventing local overheating and uneven heat dissipation.
[0031] The cross section of the above-mentioned accommodating cavity 80 is set to be circular to match the transformer module 9, and the inner wall of the accommodating cavity 80 is provided with a tooth groove 81 to match the outer contour of the conductor 911. This solution greatly reduces the thermal resistance of the primary side wire package 91 and the secondary side winding 92 to the housing 8, and increases the heat dissipation area between the two, thereby improving the heat dissipation effect of the side of the housing 8.
[0032] The cross section of the housing 8 is in the shape of an outer square and an inner tooth.
[0033] The above-mentioned accommodating cavity 80 passes through the front end of the shell 8, and the radiator includes a first radiator 1. The first radiator 1 is arranged at the front end of the shell 8 and closes the opening of the accommodating cavity 80 at the front end of the shell 8, so that the first radiator 1 and the shell 8 form an integral whole, thereby shortening the heat dissipation path and improving the heat dissipation performance. There is a gap of a preset distance between the front end of the secondary winding 92 and the first radiator 1, so that the front end of the secondary winding 92 and the first radiator 1 can maintain insulation.
[0034] The above gap is filled by a thermally conductive gasket, which is made of a flexible material, and the preset distance is less than the thickness of the thermally conductive gasket. In this solution, since the thickness of the thermally conductive gasket is greater than the preset gap, after assembly, the conductor 911 will be partially squeezed and embedded in the thermally conductive gasket, thereby increasing the contact area between the two, expanding the heat dissipation area, and at the same time, reducing the thermal resistance from the front end of the transformer module 9 to the first heat sink 1.
[0035] The first radiator 1 and the second radiator 5 are liquid-cooled radiators.
[0036] The thermally conductive gasket is a thermally conductive silicone sheet with a thermal conductivity greater than or equal to 3.0 W / mk.
[0037] The above preset distance is 1 mm, and the thickness of the thermal pad is 2 mm.
[0038] A side surface of the housing 8 is provided with a gap-avoiding portion 83 , and the electrode wires of the primary edge wire package 91 pass through the gap-avoiding portion 83 to be connected to the external circuit system.
[0039] An inner ring heat conductive block 82 is provided between the transformer module 9 and the first heat sink 1 . The inner ring heat conductive block 82 is fixedly connected to the first heat sink 1 and passes through the inner ring of the annular magnetic core 93 , thereby solving the heat dissipation problem of the inner ring surface of the transformer module 9 .
[0040] The radiator includes a second radiator 5, which is disposed on the rear side of the rear cover plate 71 and insulated from the rear cover plate 71. In this solution, radiators are disposed at both the front and rear ends of the housing 8, and the housing 8 can dissipate heat through both the front and rear ends, thereby improving the heat dissipation performance.
[0041] In one embodiment, it also includes an electrode connecting plate 72, which is arranged on the rear side of the rear cover plate 71, and one of the electrodes of the secondary winding 92 is connected to the electrode connecting plate 72 and is insulated and connected to the second heat sink 5. In this solution, the electrode connecting plate 72 is arranged on the rear side of the rear cover plate 71, so that the other electrode of the conductor 911 passes through the outlet portion and is uniformly collected to the electrode connecting plate 72, and is connected to the external circuit system through the electrode connecting plate 72. During assembly, the transformer module 9 is first assembled on the rear cover plate 71, and then the shell 8 is installed on the rear cover plate 71, and the electrode connecting plate 72 is welded to the secondary winding 92 by a positioning fixture, and then the above components are installed on the first heat sink 1, that is, the first heat sink 1, the shell 8, the transformer module 9, the rear cover plate 71, and the electrode connecting plate 72 are connected together, thereby completing the assembly of the above components.
[0042] Specifically, the secondary winding 92 includes a first winding 921 and a second winding 922. The U-shaped conductor 911 of the first winding 921 is connected to the rear cover plate 71 on one side of the inner circle of the annular magnetic core 93, and is connected to the electrode connecting plate 72 through the rear cover plate 71 on one side of the outer circle. The middle part of the rear cover plate 71 is provided with a first wiring hole 713, and the side part is provided with a first outlet portion 711. The first outlet portion 711 is a plurality of outlet holes, and the diameter of the outlet hole is greater than the diameter of the conductor 911. The second winding 922 is connected to the electrode connecting plate 72 on one side of the inner circle of the annular magnetic core 93, and is connected to the first connecting plate on one side of the outer circle. The middle part of the rear cover plate 71 is provided with a second outlet portion 712, which is an opening, and the side part is provided with a second wiring hole 714.
[0043] The electrode connecting plate 72 and the second heat sink 5 are connected by means of a heat conducting block 73 , and at least one of the butt joint surfaces of the electrode connecting plate 72 and the second heat sink 5 is provided with an insulating layer.
[0044] By covering the multiple U-shaped conductors 911 of the secondary winding 92 on the upper surface and the inner and outer circular surfaces of the primary wire package 91, the contact area between the two is increased to reduce the thermal resistance, and further make most of the internal heat of the transformer module 9 concentrated on the conductor 911, and then use the insulating thermal conductive gasket with high thermal conductivity to quickly transfer the heat to the liquid cooling radiator; by using the specially designed outer square inner toothed heat-conducting shell 8, the heat conduction path between the U-shaped conductor 911 and the primary wire package 91 can be shortened to reduce its thermal resistance and improve the heat dissipation effect of the two sides. Secondly, since the shell 8 is the negative pole, the rear cover plate 71 is installed on it, which can further solve the heat dissipation problem of the rear end surface of the primary wire package 91. Then, by adding a thermal conductive design on the rear side of the electrode connecting plate 72, the main transformer module 7 can achieve simultaneous heat dissipation on five sides at both ends. Due to the increase in the overall heat dissipation area and the reduction in thermal resistance, its heat dissipation effect is significantly improved, and the main transformer power can be increased by at least 50%.
[0045] According to the disclosure and teaching of the above description, the technical personnel in the field to which the utility model belongs can also change and modify the above implementation. Therefore, the utility model is not limited to the specific implementation methods disclosed and described above, and some modifications and changes to the utility model should also fall within the scope of protection of the claims of the utility model. In addition, although some specific terms are used in this specification, these terms are only for the convenience of description and do not constitute any limitation to the utility model.
Claims
1. A main transformer module (7) of a rectifier device, characterized in that: include: A shell (8) and a rear cover plate (71) made of a heat-conducting material, wherein the shell (8) is provided with a receiving cavity (80) penetrating the rear end thereof, and the rear cover plate (71) closes the opening of the receiving cavity (80) at the rear end of the shell (8); A transformer module (9) is arranged in the accommodating cavity (80), comprising an annular magnetic core (93), a primary wire package (91) and a secondary winding (92); the annular magnetic core (93) is fixed on a rear cover plate (71); the primary wire package (91) is wound on the annular magnetic core (93); the secondary winding (92) comprises a plurality of conductors (911); the conductors (911) are wound on the front end and two side surfaces of the primary wire package (91) in a three-sided covering manner; and the gaps between the annular magnetic core (93), the primary wire package (91), the secondary winding (92) and the inner wall of the accommodating cavity (80) are filled with an insulating and heat-conductive potting material; The radiator is arranged on the outside of the shell (8).
2. The main transformer module (7) according to claim 1, characterized in that: The shell (8) and the rear cover (71) are made of conductive materials. The rear cover (71) is provided with an outlet portion. One electrode of the secondary winding (92) is connected to the rear cover (71), and the other electrode passes through the outlet portion to be connected to an external circuit system.
3. The main transformer module (7) according to claim 2, characterized in that: The conductor (911) is U-shaped, one end of the U-shape is used as one of the electrodes and is electrically connected to the rear cover plate (71), and the other end passes through the outlet portion.
4. The main transformer module (7) according to claim 1, characterized in that: The secondary winding (92) is provided with at least two groups, which are evenly distributed with the center of the annular magnetic core (93) as the symmetric center, and three adjacent conductors (911) are arranged in a "pin" shape at a position close to the inner circle of the annular magnetic core (93).
5. The main transformer module (7) according to claim 1, characterized in that: The cross section of the accommodating cavity (80) is arranged to be circular and compatible with the transformer module (9); the inner wall of the accommodating cavity (80) is provided with tooth grooves (81) that are compatible with the outer contour of the conductor (911).
6. The main transformer module (7) according to any one of claims 1 to 5, characterized in that: The accommodating cavity (80) passes through the front end of the shell (8); the radiator comprises a first radiator (1); the first radiator (1) is arranged at the front end of the shell (8) and closes the opening of the accommodating cavity (80) at the front end of the shell (8); and a gap of a preset distance is provided between the front end of the secondary winding (92) and the first radiator (1).
7. The main transformer module (7) according to claim 6, characterized in that: The gap is filled with a thermally conductive gasket, which is made of a flexible material and has a thickness greater than the gap.
8. The main transformer module (7) according to claim 6, characterized in that: The radiator comprises a second radiator (5), wherein the second radiator (5) is arranged on the rear side of the rear cover plate (71) and is insulated from the rear cover plate (71).
9. The main transformer module (7) according to claim 8, characterized in that: It also includes an electrode connecting plate (72), which is arranged on the rear side of the rear cover plate (71), and one of the electrodes of the secondary winding (92) is connected to the electrode connecting plate (72) and is insulated from the second heat sink (5).
10. The main transformer module (7) according to claim 9, characterized in that: The electrode connecting plate (72) and the second heat sink (5) are connected by means of a heat conducting block (73), and an insulating layer is provided on at least one of the butt joint surfaces of the electrode connecting plate (72) and the second heat sink (5).