Transformer and winding structure thereof

Abstract

The winding structure comprises a magnetic core, a coil and an insulation support assembly, the magnetic core comprises a plurality of magnetic blocks, the plurality of magnetic blocks are arranged to form an annular structure and are fixedly arranged on the insulation support assembly, a gap is arranged between every two adjacent magnetic blocks, and the coil is arranged in the annular structure. The insulation support assembly is provided with a plurality of partition plates, the partition plates are correspondingly arranged in the gaps, and the coil is wound on the insulation support assembly. According to the transformer and the winding structure thereof, the power density can be improved, and miniaturization is achieved.

Description

Technical Field

[0001] The utility model relates to the technical field of transformers, in particular to a transformer and a winding structure thereof. Background Art

[0002] Modern power supply technology, especially in the field of new energy electric vehicles, has increasingly higher requirements for power density, volume, dynamic performance, magnetic component loss, etc. Among them, in new energy electric vehicles, water cooling is usually used to enhance heat dissipation capacity, and the on-board magnetic components need to be placed in an aluminum shell to fill with glue with high thermal conductivity to improve thermal conductivity. Therefore, it is necessary to make the magnetic components such as transformers used in new energy electric vehicles as high power density, small volume, low loss as possible, and improve production efficiency to reduce costs; however, existing transformers often have problems such as large power loss and large volume.

[0003] The disclosure of the above background technology content is only used to assist in understanding the concept and technical solution of the utility model. It does not necessarily belong to the prior art of this patent application. In the absence of clear evidence that the above content has been disclosed on the filing date of this patent application, the above background technology should not be used to evaluate the novelty and creativity of the present application. Utility Model Content

[0004] In order to solve the above technical problems, the utility model proposes a transformer and a winding structure thereof, which can greatly reduce power loss, improve power density and achieve miniaturization.

[0005] In order to achieve the above purpose, the utility model adopts the following technical solutions:

[0006] In the first aspect, the utility model discloses a winding structure of a transformer, including a magnetic core, a coil and an insulating support assembly, the magnetic core includes a plurality of magnetic blocks, the plurality of magnetic blocks are arranged to form a ring structure and are fixedly disposed on the insulating support assembly, and a gap is provided between each two adjacent magnetic blocks, the insulating support assembly is provided with a plurality of partitions, each of the partitions is correspondingly disposed in the gap, and the coil is wound on the insulating support assembly.

[0007] Preferably, the insulating support assembly includes a first insulating support and a second insulating support, the first insulating support includes a first substrate, a first inner ring plate and a plurality of partitions, the first inner ring plate and the plurality of partitions are respectively fixedly connected to the first side surface of the first substrate, and the plurality of partitions are respectively fixedly connected to the outer wall of the first inner ring plate, and each of the magnetic blocks is respectively fixedly arranged between each two adjacent partitions.

[0008] Preferably, the first insulating support further includes a first enclosure plate, the first enclosure plate is fixedly connected to the outer edge of the first side surface of the first substrate, and the height of the first enclosure plate is smaller than the height of the partition plate.

[0009] Preferably, a sloped or concave arc-shaped transition portion is provided at the connection position between the first enclosure and the first base plate.

[0010] Preferably, the first substrate is an annular plate, and a plurality of first flanges are protruding from an annular outer wall of the first substrate, and the plurality of first flanges are arranged at intervals to position the coil.

[0011] Preferably, the second insulating support comprises a second substrate, the second substrate is an annular plate, a plurality of second flanges are protruding from the annular outer wall of the second substrate, and the plurality of second flanges are respectively corresponding to the plurality of first flanges for jointly positioning the coil.

[0012] Preferably, the second insulating support further includes a second enclosure plate, and the second enclosure plate is fixedly connected to the outer edge of the second side surface of the second substrate.

[0013] Preferably, the second insulating support further includes a second inner annular plate, and the second inner annular plate is fixedly connected to the second side surface of the second base plate.

[0014] Preferably, the widths of the gaps between two adjacent magnetic blocks are equal.

[0015] In a second aspect, the utility model discloses a transformer, comprising the winding structure described in the first aspect.

[0016] Compared with the prior art, the beneficial effect of the utility model is that: the transformer and its winding structure disclosed by the utility model, wherein the magnetic core includes a plurality of magnetic blocks, and the plurality of magnetic blocks are arranged at intervals to form a ring structure fixedly arranged on the insulating bracket assembly, compared with the large air gap of the conventional flyback transformer, which will produce a large air gap flux loss, the utility model can reduce the power loss caused by a single large air gap by setting a plurality of air gaps. Furthermore, based on the winding structure providing a segmented air gap, it can form a DC converter main transformer with another copper shell winding completely exposed to the outside, which can greatly improve the power density, is conducive to miniaturization, and can reduce losses, improve production efficiency and reduce costs, thereby meeting the high requirements of new energy electric vehicles. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 This is a schematic diagram of a transformer winding structure according to an embodiment of the utility model;

[0018] Figure 2 yes Figure 1An exploded schematic diagram of the winding structure of the transformer;

[0019] Figure 3 yes Figure 1 A schematic diagram of the structure of the magnetic core of the winding structure of the transformer;

[0020] Figure 4 yes Figure 1 A schematic cross-sectional view of the winding structure of the transformer;

[0021] Figure 5 yes Figure 1 A schematic structural diagram of a first insulating support of a winding structure of a transformer;

[0022] Figure 6 yes Figure 1 A structural schematic diagram of a first insulating support of a winding structure of a transformer from another perspective;

[0023] Figure 7 yes Figure 1 A schematic cross-sectional view of a first insulating support of a winding structure of a transformer;

[0024] Figure 8 yes Figure 1 A cross-sectional schematic diagram of the winding structure of the transformer;

[0025] Fig. 9 yes Figure 1 A schematic structural diagram of a second insulating bracket of a winding structure of a transformer. DETAILED DESCRIPTION

[0026] The following is a detailed description of the implementation of the utility model. It should be emphasized that the following description is only exemplary and is not intended to limit the scope and application of the utility model.

[0027] It should be noted that when a component is referred to as being "fixed to" or "disposed on" another component, it can be directly on the other component or indirectly on the other component. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or indirectly connected to the other element. In addition, connection can be used for both fixing and circuit / signal communication.

[0028] It should be understood that the terms "length", "width", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the embodiments of the utility model 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 cannot be understood as a limitation on the utility model.

[0029] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of the embodiments of the present utility model, the meaning of "multiple" is two or more, unless otherwise clearly and specifically defined.

[0030] like Figure 1 and Figure 2 As shown, the utility model embodiment 1 discloses a transformer winding structure, including a magnetic core 10, a coil 20 and an insulating support assembly 30, combined with Figure 2 and Figure 3 The magnetic core 10 includes four magnetic blocks 11, which are arranged to form a ring structure and fixedly arranged on the insulating support assembly 30, and a gap 12 is provided between each two adjacent magnetic blocks 11. Figure 4 and Figure 5 The insulating support assembly 30 is provided with four partitions 313 , each partition 313 is correspondingly arranged in the gap 12 , and the coil 20 is wound on the insulating support assembly 30 along the inner and outer rings of the annular structure.

[0031] The insulating support assembly 30 includes a first insulating support 31 and a second insulating support 32, Figures 5 and 6 The first insulating support 31 includes a first substrate 311, a first inner annular plate 312 and a plurality of partitions 313. The first inner annular plate 312 and the plurality of partitions 313 are respectively fixedly connected to the first side surface of the first substrate 311, and the plurality of partitions 313 are respectively fixedly connected to the outer wall of the first inner annular plate 312. Each magnetic block 11 is respectively fixedly arranged between each two adjacent partitions 313. Further, the first insulating support 31 also includes a first enclosure 314, which is fixedly connected to the outer edge of the first side surface of the first substrate 311, and the height of the first enclosure 314 is less than the height of the partition 313. A sloped or concave arc-shaped transition portion 315 is provided at the connection position between the first enclosure 314 and the first substrate 311.

[0032] like Fig. 9As shown, the second insulating support 32 includes a second substrate 321, a second inner annular plate 322 and a second enclosure 323. The second inner annular plate 322 is fixedly connected to the second side surface of the second substrate 321, and the second enclosure 323 is fixedly connected to the outer edge of the second side surface of the second substrate 321. The first substrate 311 and the second substrate 321 are respectively annular plates. A plurality of first flanges 316 are protrudingly provided on the annular outer wall of the first substrate 311, and a plurality of second flanges 324 are protrudingly provided on the annular outer wall of the second substrate 321. The plurality of second flanges 324 and the plurality of first flanges 316 are respectively provided correspondingly to each other for co-positioning the coil. Among them, holes can be respectively provided on the first substrate 311 and the second substrate 321 to reduce the material consumption of the insulating support and the overall weight of the product, and at the same time, it is convenient for the product's potting glue to have more contact surfaces with the magnetic core, which is helpful to conduct heat of the magnetic core.

[0033] Among them, the width of each gap 12 set between each two adjacent magnetic blocks 11 is equal. Each gap 12 set between each two adjacent magnetic blocks 11 in this embodiment can be used as the air gap of the transformer. In this embodiment, four magnetic blocks 11 are set, so there are four gaps 12 in total, that is, there are four corresponding air gaps. Compared with the large air gap of the conventional flyback transformer, a large air gap flux loss will be generated. In this embodiment, the four magnetic blocks 11 are arranged to form a four-equal magnetic ring structure, and the four magnetic blocks 11 are isolated to form four equal small air gaps in combination with the four partitions 313 on the insulating bracket assembly 30, which effectively reduces the power loss caused by a single large air gap. In some other embodiments, the number of magnetic blocks 11 can also be 2, 3 or more than 4, and correspondingly, the number of gaps 12 between each adjacent magnetic block 11 is the same as the number of magnetic blocks 11, and the number of partitions 313 is the same as the number of gaps 12 between each adjacent magnetic block 11.

[0034] The insulating support assembly 30 in this embodiment includes a first insulating support 31 and a second insulating support 32, wherein the first insulating support 31 can be an upper support, and the second insulating support 32 corresponds to a lower support. Correspondingly, the first substrate 311 is an upper substrate, and the second substrate 321 is a lower substrate. The four partitions 313 are integrally connected to the upper support, which can simplify the production process and reduce labor costs; further, each structure in the first insulating support 31 is an integrally formed structure, and each structure included in the second insulating support 32 can also be an integrally formed structure. In other embodiments, the partition 313 can also be integrally connected to the lower support. The coil 20 can be formed by winding three layers of insulated stranded wire along the inner and outer rings of the insulating support assembly 30 of the ring structure. During the winding process, the positions of the first flange 316 and the second flange 324 can be used as reference positions for positioning.

[0035] Combination Figure 7 and Figure 8As shown, a transition portion 315 of a slope or concave arc is provided at the connection position between the first enclosure 314 and the first substrate 311, so that the magnetic block 11 can automatically slide inward when installed in the first insulating bracket 31, avoiding the use of additional thrust to squeeze the magnetic block 11 to meet the inductance requirements, and effectively improving production efficiency; and then the second insulating bracket 32 ​​is put on, and the magnetic core 10 can be clamped between the first insulating bracket 31 and the second insulating bracket 32, and then the coil is wound along the outer wall of the first insulating bracket 31 and the second insulating bracket 32 ​​and the inner wall of the first inner annular plate 312 and the second inner annular plate 322, so that each magnetic block 11 is further close to the partition 313. Among them, the inductance value of the transformer product is mainly determined by the air gap. In practical applications, the width of the gap between each magnetic block 11 can be stabilized by controlling the thickness of the partition 313 to ensure that the inductance requirements are met.

[0036] Specifically, the first insulating bracket 31 and the second insulating bracket 32 ​​are respectively made of plastic materials with insulating properties, so that when the magnetic core 10 is clamped between the first insulating bracket 31 and the second insulating bracket 32, the magnetic core 10 and the coil 20 are also isolated, preventing the coil 20 from being scratched by the magnetic core 10, thereby strengthening the insulation between the magnetic core 10 and the coil 20.

[0037] In other embodiments, the shape of the magnetic core 10 and the number of air gaps can be adjusted according to different powers and air gap sizes. For example, multiple magnetic blocks 11 can be arranged to form a circular ring structure, an elliptical ring structure, a square ring structure, or a racetrack structure, etc., which is not limited here.

[0038] Embodiment 2 of the present utility model discloses a transformer, including the winding structure in embodiment 1. The winding structure in embodiment 1 provides a segmented air gap and isolates the magnetic core and the coil. The winding structure is the primary of the transformer, which can form a DC conversion transformer with another copper shell winding completely exposed to the outside, which can greatly improve the power density, facilitate miniaturization, reduce losses, improve production efficiency and reduce costs, thereby meeting the high requirements of new energy electric vehicles.

[0039] The background section of the utility model may contain background information about the problem or environment of the utility model, rather than describing the prior art by others. Therefore, the content contained in the background technology section is not an admission of the applicant to the prior art.

[0040] The above content is a further detailed description of the utility model in combination with specific / preferred embodiments, and it cannot be determined that the specific implementation of the utility model is limited to these descriptions. For ordinary technicians in the technical field to which the utility model belongs, without departing from the concept of the utility model, it can also make several substitutions or modifications to these described embodiments, and these substitutions or modifications should be regarded as belonging to the protection scope of the utility model. In the description of this specification, the description of the reference terms "an embodiment", "some embodiments", "preferred embodiments", "examples", "specific examples", or "some examples" means that the specific features, structures, materials or characteristics described in combination with the embodiment or example are included in at least one embodiment or example of the utility model. In this specification, the schematic representation of the above terms does not necessarily target the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, in the absence of mutual contradiction, the technical personnel in this field can combine and combine the different embodiments or examples described in this specification and the features of different embodiments or examples. Although the embodiments of the present invention and their advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the scope defined by the appended claims.

Claims

1. A transformer winding structure, characterized in that: It includes a magnetic core, a coil and an insulating support assembly, the magnetic core includes a plurality of magnetic blocks, the plurality of magnetic blocks are arranged to form a ring structure and are fixedly arranged on the insulating support assembly, and a gap is provided between each two adjacent magnetic blocks, the insulating support assembly is provided with a plurality of partitions, each of the partitions is correspondingly arranged in the gap, and the coil is wound on the insulating support assembly.

2. The winding structure according to claim 1, characterized in that: The insulating support assembly includes a first insulating support and a second insulating support, the first insulating support includes a first base plate, a first inner ring plate and a plurality of partitions, the first inner ring plate and the plurality of partitions are respectively fixedly connected to the first side surface of the first base plate, and the plurality of partitions are respectively fixedly connected to the outer wall of the first inner ring plate, and each of the magnetic blocks is respectively fixedly arranged between each two adjacent partitions.

3. The winding structure according to claim 2, characterized in that: The first insulating support further includes a first enclosure plate, which is fixedly connected to the outer edge of the first side surface of the first substrate, and the height of the first enclosure plate is smaller than the height of the partition plate.

4. The winding structure according to claim 3, characterized in that: A sloped or concave arc-shaped transition portion is provided at the connection position between the first enclosure and the first base plate.

5. The winding structure according to claim 2, characterized in that: The first substrate is an annular plate, and a plurality of first flanges are protruding from an annular outer wall of the first substrate. The plurality of first flanges are arranged at intervals to position the coil.

6. The winding structure according to claim 5, characterized in that: The second insulating support includes a second substrate, which is an annular plate. A plurality of second flanges are protruding from an annular outer wall of the second substrate. The plurality of second flanges are respectively corresponding to the plurality of first flanges for jointly positioning the coil.

7. The winding structure according to claim 6, characterized in that: The second insulating support further includes a second enclosure plate, and the second enclosure plate is fixedly connected to the outer edge of the second side surface of the second substrate.

8. The winding structure according to claim 6, characterized in that: The second insulating support further includes a second inner annular plate, and the second inner annular plate is fixedly connected to the second side surface of the second base plate.

9. The winding structure according to claim 1, characterized in that: The widths of the gaps between two adjacent magnetic blocks are equal.

10. A transformer, characterized in that: The invention comprises the winding structure as claimed in any one of claims 1 to 9.

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