Integrated transformer and transformer module
By spiral winding of the wire cake formed on multiple parallel cores and continuously winding between the cores to form an integrated structure, the capacity limitation and reliability problems existing in traditional transformers in high power and compact size applications are solved, and a transformer design with higher power and smaller volume is achieved.
Patent Information
- Application Number
- CN202421443038.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-06-21
- Publication Date
- 2025-04-29
- Estimated Expiration
- 2034-06-21
AI Technical Summary
Traditional transformers have capacity limitations and reliability issues in high power and compact size applications, and existing integrated capacity expansion methods are complex and difficult to flexibly configure coil lengths.
Multiple iron cores arranged in parallel are used to wind the wire cake in a spiral manner, and continuously wind the wire between the iron cores to form an integrated structure to form a series-connected wire string, simplify the capacity expansion manufacturing process, avoid contact problems, and flexibly adjust the coil length.
Improves the power and reliability of the transformer, simplifies manufacturing processes, and significantly improves the performance of the transformer in high-power and compact size applications.
Smart Images
Figure CN222813403U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of transformers, and in particular to an integrated transformer and a transformer module. Background Art
[0002] In a switching power supply, the transformer is the core device for power transmission, conversion, and filtering. Its design and manufacturing process are crucial to the performance and reliability of the entire system. With the market demand for miniaturized transformers with high power density, the integration and expansion of traditional transformers have certain limitations.
[0003] At present, there are two main ways to integrate and expand transformers. One is to connect the joints of multiple single transformers together by welding flying wire aerial joints. The main problem with this method is that the operation is complex and it is difficult to flexibly configure the length of the transformer coil. In addition, due to the easy occurrence of poor contact at the welding joint, the reliability of the transformer is reduced. The form of flying wire welding not only increases the process difficulty in the manufacturing process, but may also affect the stability and service life of the transformer in actual applications.
[0004] The second method is to increase the capacity of the transformer by increasing the number of coil turns in a single core. However, the diameter of the center column of the core is limited, and the power of the transformer is closely related to the cross-sectional area of the center column. When the height dimension is strictly limited, there is an obvious upper limit to the method of increasing the number of coil turns. Although this method can increase the power of the transformer to a certain extent, it is limited by the physical size of the core and cannot meet the application requirements of higher power and smaller volume.
[0005] Therefore, it is necessary to improve the structure of large-capacity transformers. Utility Model Content
[0006] The purpose of the utility model is to provide an integrated transformer and a transformer module which can effectively improve the capacity of the transformer and are efficient and reliable.
[0007] In order to achieve the above object, the utility model provides an integrated transformer, which includes at least two iron cores arranged in parallel, each of the iron cores has a central column and a coil used as a primary coil or a secondary coil wound in a spiral manner on the central column, and the ends of the coils on the two adjacent iron cores are collinear with the starting ends, so that the coils in several of the iron cores are connected in series;
[0008] A plurality of the wire coils connected in series form a wire string, wherein the wire coil at one end of the wire string is provided with a first connector, and the wire coil at the other end of the wire string is provided with a second connector.
[0009] Preferably, the coils in each of the cores have the same number of turns.
[0010] The utility model also provides a transformer module, which includes a transformer and a heat sink, wherein the transformer includes at least two parallel iron cores, each of which has a central column and a coil used as a primary coil or a secondary coil wound in a spiral manner on the central column, and the ends of the coils on two adjacent iron cores are in line with the starting end, so that the coils in a plurality of the iron cores are connected in series;
[0011] A plurality of the wire coils connected in series form a wire string, wherein the wire coil at one end of the wire string is provided with a first connector, and the wire coil at the other end of the wire string is provided with a second connector;
[0012] A first PCB board and a second PCB board connected to the radiator are respectively arranged on two back-to-back sides of the radiator; the transformer is arranged on the first PCB board;
[0013] A plurality of capacitors are arranged on the second PCB board, and the plurality of capacitors are used to provide output capacitance for the transformer.
[0014] Preferably, the coils in each of the cores have the same number of turns.
[0015] Preferably, the second PCB board is connected to the heat sink via a bridging bolt and a bridging nut, and the capacitor is located between the second PCB board and the heat sink.
[0016] Preferably, the bridge nut is in the shape of a cylinder with two ends open, and the bridge nut is arranged between the second PCB board and the heat sink to form a space for accommodating the capacitor between the second PCB board and the heat sink;
[0017] One of the bridging bolts passes through the second PCB board and enters the bridging nut;
[0018] Another of the bridging bolts passes through the heat sink and enters into the bridging nut.
[0019] Preferably, the first PCB board and / or the second PCB board abuts against the heat sink via a thermally conductive pad.
[0020] Compared with the prior art, the transformer provided by the above technical solution of the utility model forms a coil by spirally winding on multiple parallel iron cores, and continuously winding between the iron cores to form an integrated structure. This not only simplifies the transformer capacity expansion manufacturing process and avoids the poor contact problem caused by traditional flying wire welding, but also can flexibly adjust the coil length, thereby improving the power and reliability of the transformer and significantly improving the performance of the transformer in high-power and compact size applications. BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Figure 1 It is a schematic diagram of the planar structure of the transformer in the embodiment of the utility model.
[0022] Figure 2 for Figure 1 Exploded view of one of the cores.
[0023] Figure 3 for Figure 1 Connection diagram of the median pie.
[0024] Figure 4 This is an assembly structure diagram of the transformer module in an embodiment of the utility model.
[0025] Figure 5 for Figure 4 Exploded view of the transformer module. DETAILED DESCRIPTION
[0026] In order to explain the technical content, structural features, achieved objectives and effects of the present invention in detail, the following is a detailed description in conjunction with the implementation modes and the accompanying drawings.
[0027] This embodiment discloses an integrated transformer, which can be used in switching power supplies and other occasions where the power density of the transformer is required to be high. Figures 1 to 3 The transformer M comprises at least two parallel-arranged iron cores 1, each of which has a central column 2 and a coil 3 spirally wound on the central column 2 and used as a primary coil or a secondary coil. The ends of the coils 3 on two adjacent iron cores 1 are collinear with the starting ends, so that the coils 3 in several iron cores 1 are connected in series.
[0028] A plurality of bobbins 3 connected in series form a wire string. A first connector J1 is provided on the bobbins 3 at one end of the wire string, and a second connector J2 is provided on the bobbins 3 at the other end of the wire string.
[0029] For the transformer M with the above structure, the coil 3 is spirally wound on multiple parallel iron cores 1, and is continuously wound between the iron cores 1 to form an integrated structure. This not only simplifies the manufacturing process of transformer M expansion and avoids the poor contact problem caused by traditional flying wire welding, but also enables flexible adjustment of the coil length, thereby improving the power and reliability of the transformer M and significantly improving the performance of the transformer M in high-power and compact size applications.
[0030] On the other hand, the number of turns of the coils 3 in each core 1 is the same, which further enhances the consistency and stability of the transformer M. Specifically, this design ensures that the coils 3 on each core 1 have the same electrical characteristics, avoiding the voltage and current imbalance problems caused by inconsistent turns of the coils 3. The uniform coil 3 turns design helps to achieve a smoother magnetic flux distribution, reduces the risk of magnetic saturation and leakage, and improves the overall efficiency and reliability of the transformer M. In addition, this consistent design also simplifies the production and quality control process, ensuring that each production batch of transformer M can meet the expected performance standards and meet strict application requirements. In general, the design with consistent turns further optimizes the performance of the transformer M and improves its adaptability in high power density and compact size applications.
[0031] In this embodiment, two cores 1 are taken as an example, and for the convenience of explanation, they are named as the first core 1 and the second core 1' respectively. When assembling such a transformer M, firstly, a coil 3 including 14 turns of coil is wound on the central column 2 of the first core 1. After the 14th turn is wound, the end wire is introduced into the central column 2 on the second core 1', and then the coil is wound on the central column 2 of the second core 1', and 14 turns are also wound to form another coil 3'. Finally, the starting end of the coil 3 on the first core 1 forms the first joint J1, and the end of the coil 3' on the second core 1' forms the second joint J2. It should be noted that the first joint J1 and the second joint J2 are used as the positive and negative poles of the transformer M, respectively.
[0032] In another embodiment of the utility model, Figure 4 and Figure 5 , also discloses a transformer module, including a transformer M having the above structure and a heat sink 5. A first PCB board 40 and a second PCB board 41 connected to the heat sink 5 are respectively arranged on both sides of the heat sink 5; the transformer M is arranged on the first PCB board 40.
[0033] A plurality of capacitors 6 are disposed on the second PCB board 41 , and the plurality of capacitors 6 are used to provide output capacitance for the transformer M.
[0034] In this embodiment, the transformer M is provided with a capacitor 6 and a heat sink 5 to form a transformer module.
[0035] The heat dissipation capacity of the transformer module is effectively improved by arranging the heat sink 5 between the transformer M and the capacitor 6. The design of the heat sink 5 can timely remove the heat generated by the transformer M and the capacitor 6 during operation, thereby reducing the operating temperature of the components, extending their service life, and improving the reliability of the system.
[0036] Secondly, the first PCB board 40 and the second PCB board 41 are respectively arranged on the back-to-back sides of the heat sink 5, which not only saves space but also makes the structure of the transformer M more compact.
[0037] In general, this design achieves thermal management optimization, electrical performance improvement and compact structure by arranging PCB boards on both sides of the heat sink 5, and further enhances the adaptability of the transformer M in high-density and high-power applications.
[0038] On the other hand, the second PCB board 41 is connected to the heat sink 5 through the bridging bolt 71 and the bridging nut 70 , and the capacitor 6 is located between the second PCB board 41 and the heat sink 5 .
[0039] Specifically, the bridging nut 70 is in the shape of a cylinder with two ends open, and the bridging nut 70 is disposed between the second PCB board 41 and the heat sink 5 to form a space for accommodating the capacitor 6 between the second PCB board 41 and the heat sink 5;
[0040] One of the bridging bolts 71 passes through the second PCB board 41 and enters the bridging nut 70, thereby fixing one end of the bridging nut 70 to the second PCB board 41;
[0041] Another bridging bolt 71 passes through the radiator 5 and enters the bridging nut 70 , thereby fixing the other end of the bridging nut 70 to the radiator 5 .
[0042] In this embodiment, by setting a bridging nut 70 between the second PCB board 41 and the heat sink 5 and forming a space for accommodating the capacitor 6, the available space inside the transformer module is effectively utilized, making the design more compact, saving external space, and improving the layout efficiency of the components. Secondly, the capacitor 6 is close to the heat sink 5, which helps the heat generated by the capacitor 6 to be quickly transferred to the heat sink 5, improves the overall heat dissipation efficiency, reduces the operating temperature of the capacitor 6, and thus prolongs its service life and stability. In addition, the design of the bridging bolt 71 and the bridging nut 70 ensures a firm connection between the second PCB board 41 and the heat sink 5, increases the mechanical strength and anti-seismic ability of the transformer module, and prevents loosening and damage caused by vibration during operation.
[0043] In general, through the optimized structural design in this embodiment, more efficient space utilization and heat dissipation effects are achieved, the mechanical strength and electrical performance of the transformer module are improved, the installation and maintenance process is simplified, and the adaptability and reliability of the transformer module are enhanced.
[0044] On the other hand, the first PCB board 40 and / or the second PCB board 41 abut against the heat sink 5 through the thermal pad 8 to quickly transfer the heat on the first PCB board 40 and / or the second PCB board 41 to the heat sink. The thermal pad 8 in this embodiment is preferably a thermally conductive silicone sheet.
[0045] The above disclosure is only the preferred embodiment of the present invention, which certainly cannot be used to limit the scope of rights of the present invention. Therefore, equivalent changes made according to the scope of the patent application of the present invention are still within the scope covered by the present invention.
Claims
1. An integrated transformer, characterized in that: The invention comprises at least two parallelly arranged iron cores, each of which has a central column and a coil used as a primary coil or a secondary coil wound in a spiral manner on the central column, and the ends of the coils on two adjacent iron cores are in line with the starting ends, so that the coils in several of the iron cores are connected in series; A plurality of the coils connected in series form a coil string, the coil at one end of the coil string is provided with a first connector, and the coil at the other end of the coil string is provided with a second connector.
2. The integrated transformer according to claim 1, characterized in that: The number of turns of the coils in each of the iron cores is the same.
3. A transformer module, characterized in that: The transformer comprises a transformer and a heat sink, wherein the transformer comprises at least two parallel iron cores, each of the iron cores having a central column and a coil used as a primary coil or a secondary coil wound in a spiral manner on the central column, and the ends of the coils on two adjacent iron cores are in line with the starting ends, so that the coils in a plurality of the iron cores are connected in series; A plurality of the wire coils connected in series form a wire string, wherein the wire coil at one end of the wire string is provided with a first connector, and the wire coil at the other end of the wire string is provided with a second connector; A first PCB board and a second PCB board connected to the radiator are respectively arranged on two back-to-back sides of the radiator; the transformer is arranged on the first PCB board; A plurality of capacitors are arranged on the second PCB board, and the plurality of capacitors are used to provide output capacitance for the transformer.
4. The transformer module according to claim 3, characterized in that: The number of turns of the coils in each of the iron cores is the same.
5. The transformer module according to claim 3, characterized in that: The second PCB board is connected to the heat sink through a bridging bolt and a bridging nut, and the capacitor is located between the second PCB board and the heat sink.
6. The transformer module according to claim 5, characterized in that: The bridging nut is in a cylindrical shape with two ends opened, and the bridging nut is arranged between the second PCB board and the heat sink to form a space for accommodating the capacitor between the second PCB board and the heat sink; One of the bridging bolts passes through the second PCB board and enters the bridging nut; Another of the bridging bolts passes through the heat sink and enters into the bridging nut.
7. The transformer module according to claim 3, characterized in that: The first PCB board and / or the second PCB board abuts against the heat sink via a thermally conductive pad.