Vehicle-mounted transformer

Abstract

The utility model discloses a vehicle-mounted transformer which comprises a base, first to sixth magnetic cores arranged on the base, first to second frameworks and first to second windings, the first magnetic core and the second magnetic core are arranged in parallel, and the third magnetic core is attached to the first end of the first magnetic core and the first end of the second magnetic core. The fourth magnetic core and the fifth magnetic core are arranged in parallel, and the sixth magnetic core is attached to the first end of the fourth magnetic core and the first end of the fifth magnetic core; the second end of the first magnetic core is attached to the second end of the fourth magnetic core, and the second end of the second magnetic core is attached to the second end of the fifth magnetic core. A first framework sleeves the outer sides of the first magnetic core and the fourth magnetic core, and a second framework sleeves the outer sides of the second magnetic core and the fifth magnetic core; the first winding is wound on the first framework, and the second winding is wound on the second framework. The vehicle-mounted transformer is simple in structure, good in forming, simple in process procedure, very good in consistency and convenient in quality control, and reliable use of products is guaranteed.

Description

Technical Field

[0001] The utility model relates to the technical field of transformers, in particular to a vehicle-mounted transformer. Background Art

[0002] At present, many of the magnetic cores of existing devices are UU-shaped molded magnetic cores. The strength of this type of magnetic core during the raw material molding and sintering process will be affected by the size and pressing method. The process of manufacturing into products will generate heat under high-voltage conditions (because this type of product needs to be used with silicone potting to conduct heat to the water-cooled plate). The heat will cause stress in the silicone and structure, and finally cause product reliability failure, dark cracks in the magnetic core, and a decrease in inductance. Inductance is an important parameter in the transformer. Abnormalities will affect the normal working efficiency and seriously affect the operation of the on-board charger, resulting in abnormalities. Utility Model Content

[0003] The utility model aims to solve the problem of improving the reliability of a vehicle-mounted transformer and provides a vehicle-mounted transformer.

[0004] In order to achieve the above purpose, the utility model adopts the following technical solutions:

[0005] A vehicle-mounted transformer comprises: a base, and first to sixth magnetic cores, first to second frames and first to second windings arranged on the base;

[0006] The first magnetic core is arranged in parallel with the second magnetic core, the third magnetic core is arranged perpendicular to the first magnetic core and the second magnetic core, and is attached to the first end of the first magnetic core and the first end of the second magnetic core; the fourth magnetic core is arranged in parallel with the fifth magnetic core, the sixth magnetic core is arranged perpendicular to the fourth magnetic core and the fifth magnetic core, and is attached to the first end of the fourth magnetic core and the first end of the fifth magnetic core; the second end of the first magnetic core is attached to the second end of the fourth magnetic core, and the second end of the second magnetic core is attached to the second end of the fifth magnetic core;

[0007] The first frame is sleeved on the outer sides of the first magnetic core and the fourth magnetic core, and the second frame is sleeved on the outer sides of the second magnetic core and the fifth magnetic core;

[0008] The first winding is wound on the first frame, and the second winding is wound on the second frame.

[0009] In some embodiments, at least one of the third magnetic core and the sixth magnetic core includes a first magnetic core unit and a second magnetic core unit that are arranged in parallel and in close contact with each other.

[0010] In some embodiments, the first magnetic core, the second magnetic core, the fourth magnetic core, and the fifth magnetic core are elliptical center column magnetic cores, and the third magnetic core and the sixth magnetic core are I-piece magnetic cores.

[0011] In some embodiments, the two ends of the first skeleton extend outward to form a first limiting portion and a second limiting portion, respectively, and the two ends of the second skeleton extend outward to form a third limiting portion and a fourth limiting portion, respectively. The first limiting portion and the third limiting portion are used to respectively limit the short sides of the third magnetic core and jointly limit a long side, and the third limiting portion and the fourth limiting portion are used to respectively limit the short sides of the sixth magnetic core and jointly limit a long side.

[0012] In some embodiments, a shielding sheet is further disposed between the first frame, the second frame, and the base, the first frame and the second frame are fixed to a first surface of the shielding sheet, and a second surface of the shielding sheet is disposed on the base.

[0013] In some embodiments, the base is further fixedly provided with one or two blade terminals on a surface away from the first to second skeletons, and the blade terminals are used to make electrical connections with the first winding or the second winding output wire. The blade terminals include a first connecting portion and a second connecting portion arranged perpendicular to the first connecting portion, the first connecting portion and the second connecting portion are connected via a bending portion, the first connecting portion is used to make electrical connections with the winding output wire, and the second connecting portion is used to be fixedly connected to the base.

[0014] In some embodiments, a first protruding structure and a second protruding structure are respectively provided on both sides of the second connecting portion, and the base is provided with a first card slot that cooperates with the first protruding structure, and a second card slot that cooperates with the second protruding structure; a connecting hole is also provided on the second connecting portion, and a base extension portion is provided on the base in a direction perpendicular to the base, and a hook that is engaged with the connecting hole is provided at the end of the base extension portion.

[0015] In some embodiments, the bending portion includes a first bending structure and a second bending structure, the first bending structure and the second bending structure are arranged perpendicular to the second connecting portion, the first bending structure is fixedly connected to the first connecting portion, and the second bending structure is fixedly connected to the second connecting portion, when the blade terminal is connected to the base, the second bending structure can fit the surface of the base, and the first bending structure is higher than the second bending structure and is parallel to the surface of the base.

[0016] In some embodiments, the third magnetic core is bonded to the first end of the first magnetic core and the first end of the second magnetic core through a first bonding block, the sixth magnetic core is bonded to the first end of the fourth magnetic core and the first end of the fifth magnetic core through a second bonding block, the second end of the first magnetic core and the second end of the fourth magnetic core are bonded through a third bonding block, and the second end of the second magnetic core and the second end of the fifth magnetic core are bonded through a fourth bonding block; the first to fourth bonding blocks are structural parts made of epoxy resin silicone baking adhesive and cured.

[0017] In some embodiments, mesh holes are disposed on surfaces of the first skeleton and the second skeleton.

[0018] The utility model has the following beneficial effects:

[0019] The vehicle-mounted transformer of this embodiment divides the magnetic core into first to sixth magnetic cores and designs reasonable skeleton, magnetic core and winding structures to make its structure simple and well formed, with excellent strength, simple process and very good consistency, convenient quality control and ensure the reliability of product use. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 is a schematic diagram of the three-dimensional structure of the vehicle-mounted transformer from one viewing angle in this embodiment;

[0021] Figure 2 is a schematic diagram of the three-dimensional structure of the vehicle-mounted transformer from another viewing angle in this embodiment;

[0022] Figure 3 is a schematic diagram of the three-dimensional structure of the vehicle-mounted transformer from another viewing angle in this embodiment;

[0023] Figure 4 An exploded rendering of the vehicle-mounted transformer in this embodiment;

[0024] Figure 5 is an exploded line diagram of the vehicle-mounted transformer in this embodiment;

[0025] Figure 6 It is a front view of the vehicle-mounted transformer in this embodiment;

[0026] Figure 7 is a top view of the vehicle-mounted transformer in this embodiment;

[0027] Figure 8 is a bottom view of the vehicle-mounted transformer in this embodiment;

[0028] Fig. 9 It is a left side view of the vehicle-mounted transformer in this embodiment;

[0029] Fig.10 It is a right side view of the vehicle-mounted transformer in this embodiment;

[0030] Fig.11 is an assembly diagram of the magnetic core and the frame from one perspective in this embodiment;

[0031] Fig.12 is an assembly diagram of the magnetic core and the skeleton from another perspective in this embodiment;

[0032] Fig.13 This is an assembly diagram of the blade terminal and the base from one perspective in this embodiment;

[0033] Fig.14 for Fig.13 A partial enlarged view of the middle circle A;

[0034] Fig.15 This is a schematic structural diagram of the blade terminal from one viewing angle in this embodiment;

[0035] Fig.16 is a schematic structural diagram of the blade terminal from another perspective in this embodiment;

[0036] Fig.17 is a schematic structural diagram of a base from a viewing angle in this embodiment;

[0037] Fig.18 for Fig.17 A partial enlarged view of the middle circle B;

[0038] Fig.19 is an assembly cross-sectional view of the blade terminal and the base in this embodiment;

[0039] Fig. 20 is an assembly diagram of the blade terminal and the winding in this embodiment;

[0040] Fig.21 is a schematic diagram of a three-dimensional structure of the first frame and the second frame in this embodiment from one viewing angle;

[0041] Fig. 22 is a schematic diagram of the three-dimensional structure of the first skeleton and the second skeleton in another viewing angle of the present embodiment;

[0042] Fig.23 This is an assembly diagram of the skeleton and windings from one perspective in this embodiment;

[0043] Fig.24 is an assembly diagram of the skeleton and the winding from another perspective in this embodiment;

[0044] Fig.25 is an assembly diagram of the first to sixth magnetic cores from a viewing angle in this embodiment;

[0045] Fig.26 is an assembly diagram of the first to sixth magnetic cores from another perspective in this embodiment;

[0046] Fig. 27 is a structural schematic diagram of the base from another perspective in this embodiment;

[0047] Fig.28 is an assembly diagram of the base and the shielding sheet from a viewing angle in this embodiment;

[0048] Fig.29 is an assembly diagram of the base and the shielding sheet from another perspective in this embodiment;

[0049] Description of reference numerals:

[0050] 1-base, 11-first card slot, 12-second card slot, 13-extension part, 131-hook, 14-base protrusion, 15-glue filling vent, 16-auxiliary part, 17-rib, 181-first positioning pin, 182-second positioning pin, 19-limiting structure, 21-first magnetic core, 22-second magnetic core, 23-third magnetic core, 231-first magnetic core unit, 232-second magnetic core unit, 24-fourth magnetic core, 25-fifth magnetic core, 26-sixth magnetic core, 31-first skeleton, 311-first limiting part, 312-second limiting part, 313-first baffle, 314-first wiring limiting part, 315-first fixing part, 32-second skeleton, 321-third limiting part, 322-fourth limiting part, 323-second baffle, 324-second routing limiting part, 325-second fixing part, 41-first winding, 42-second winding, 5-shielding sheet, 6-blade terminal, 61-first connecting part, 62-second connecting part, 621-first protruding structure, 622-second protruding structure, 623-connecting hole, 624-first bending structure, 625-second bending structure, 7-fixed fitting block, 71-first fitting block, 72-second fitting block, 73-third fitting block, 74-fourth fitting block. DETAILED DESCRIPTION

[0051] 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.

[0052] It should be noted that when an element is referred to as being "fixed to" or "disposed on" another element, it can be directly on the other element or indirectly on the other element. 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 fixing as well as for coupling or communication.

[0053] 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.

[0054] 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.

[0055] The embodiment of the utility model corresponds to the transformer device in the vehicle charger, which plays the function of voltage conversion in the circuit. At present, many of the magnetic cores of existing devices are UU-shaped molded magnetic cores, which have low reliability. In the prior art, there are two ways: independent resonant inductor, main transformer, and integration of resonant inductor and main transformer. The actual size and space occupied will be larger. In order to solve the above problems, the embodiment of the utility model provides a vehicle transformer, reference Figure 1-Figure 10 , comprising: a base 1, and first to sixth magnetic cores, first to second frames and first to second windings arranged on the base 1;

[0056] The first magnetic core 21 is arranged in parallel with the second magnetic core 22, the third magnetic core 23 is arranged perpendicular to the first magnetic core 21 and the second magnetic core 22, and is attached to the first end of the first magnetic core 21 and the first end of the second magnetic core 22; the fourth magnetic core 24 is arranged in parallel with the fifth magnetic core 25, the sixth magnetic core 26 is arranged perpendicular to the fourth magnetic core 24 and the fifth magnetic core 25, and is attached to the first end of the fourth magnetic core 24 and the first end of the fifth magnetic core 25; the second end of the first magnetic core 21 is attached to the second end of the fourth magnetic core 24, and the second end of the second magnetic core 22 is attached to the second end of the fifth magnetic core 25;

[0057] The first magnetic core 21 and the fourth magnetic core 24 are covered with a first frame 31 , and the second magnetic core 22 and the fifth magnetic core 25 are covered with a second frame 32 ;

[0058] The first winding 41 is wound on the first frame 31 , and the second winding 42 is wound on the second frame 32 .

[0059] In some embodiments, at least one of the third magnetic core 23 and the sixth magnetic core 26 includes a first magnetic core unit and a second magnetic core unit that are arranged in parallel. In this embodiment, the third magnetic core 23 includes a first magnetic core unit 231 and a second magnetic core unit 232 that are arranged in parallel. In other embodiments, the sixth magnetic core 26 includes a first magnetic core unit and a second magnetic core unit that are arranged in parallel. In other embodiments, the third magnetic core 23 and the sixth magnetic core 26 both include a first magnetic core unit and a second magnetic core unit that are arranged in parallel. In this embodiment, the magnetic core is decomposed into blocks and then spliced ​​with epoxy resin silicone baking glue. In this embodiment, a further cut is made in the middle of the third magnetic core 23. The surface area of ​​the magnetic core increases and the magnetic core loss is further reduced, which can ensure that the stress resistance effect is guaranteed in the AEC-Q200 series experiments, thereby ensuring the high reliability of the product in the field of application.

[0060] In the embodiment of the utility model, the first magnetic core 21, the second magnetic core 22, the fourth magnetic core 24, and the fifth magnetic core 25 are elliptical central column magnetic cores with the same size and shape; the third magnetic core 23 and the sixth magnetic core 26 are I-piece magnetic cores with the same size and shape. The first to sixth magnetic cores in this embodiment are all manganese-zinc ferrite cores (made of iron, manganese, zinc oxides and their salts, using ceramic technology. It has a high initial magnetic permeability. It is generally used in the frequency range of 1 kHz to 10 MHz. It can be used to make inductors, transformers, filter cores, magnetic heads and antenna rods. It is usually called ferrite cores). The high-tech density of transformers in the automotive field is relatively low, and high-frequency, high-temperature and low-loss magnetic cores must be selected to meet the design requirements;

[0061] refer to Figure 11-Figure 12 In the embodiment of the utility model, the two ends of the first skeleton 31 extend outward to form a first limiting portion 311 and a second limiting portion 312, respectively, and the two ends of the second skeleton 32 extend outward to form a third limiting portion 321 and a fourth limiting portion 322, respectively. The first limiting portion 311 and the third limiting portion 321 are used to limit the short sides of the third magnetic core 23, respectively, and limit a long side together. The third limiting portion 321 and the fourth limiting portion 322 are used to limit the short sides of the sixth magnetic core 26, respectively, and limit a long side together. In this embodiment, the skeleton is a plastic structural part. The first skeleton 31 and the second skeleton 32 have similar structures (they have the same functional components, but the wiring method is different). They are used to isolate the winding and the carrier of the magnetic core, and play the role of automatic winding and hanging. The first skeleton 31 and the second skeleton 32 are separate individuals. After the winding forms the winding, the corresponding wires are combined into a parallel structure and then the magnetic core is assembled. After the combination, the corresponding two sides cooperate with the magnetic core to limit. In the embodiment of the utility model, the surfaces of the first frame 31 and the second frame 32 are both provided with grid holes, which can effectively prevent internal heat accumulation and facilitate glue penetration and heat dissipation system to be discharged.

[0062] refer to Figure 5 In the embodiment of the utility model, a shielding sheet 5 is also arranged between the first skeleton 31, the second skeleton 32 and the base 1, the first skeleton 31 and the second skeleton 32 are fixed to the first surface of the shielding sheet 5, the second surface of the shielding sheet 5 is arranged on the base 1, and the length of the shielding sheet 5 does not exceed the length of the first winding 41 and the second winding 42. The shielding sheet 5 in this embodiment is a shielding copper sheet, which uses C1100 copper surface passivation (the magnetic leakage of the wire package magnetic structure is large, and a shielding design is required to stabilize the leakage inductance parameters and reduce eddy current losses), the height direction is between 10 and 20 mm, and the thickness is between 0.3 and 1 mm. In this embodiment, the base 1 is a plastic structural part, which plays the role of fixing and supporting the transformer body and isolating and insulating. The base 1 can be used as a carrier of the product and a fixed position of the transformer winding inlet and outlet to achieve electrical distance protection (in this embodiment, it is a plastic part with a CTI electrical trace indication of 400 or more).

[0063] refer to Figure 5 and Figure 13-Figure 16 In the embodiment of the utility model, a blade terminal 6 is fixedly provided on a surface of the base 1 away from the first to second skeletons 32. The blade terminal 6 is used to make an electrical connection with the winding output line. The blade terminal 6 includes a first connecting portion 61 and a second connecting portion 62 arranged perpendicular to the first connecting portion 61. The first connecting portion 61 is connected to the second connecting portion 62 through a bending portion. The first connecting portion 61 is used to make an electrical connection with the winding output line, and the second connecting portion 62 is used to be fixedly connected to the base 1. The first connection part 61 in this embodiment is cylindrical, which can be connected by plugging in with the user, making it more convenient to use and disassemble. The first winding 41 and the second winding 42 in this embodiment are film-wrapped twisted wires (a single enameled wire that can reduce the skin effect at high frequencies, formed by twisting multiple enameled wires with an equivalent cross-sectional area of ​​overcurrent through a low ACR (Attenuation to crosstalk ratio), and then coated according to the overlap rate required by safety regulations). It can be a film-wrapped round wire or a film-wrapped square wire, and can be made of different insulating materials such as PET (polyethylene terephthalate) or KAPTON (polyimide). The blade terminal 6 in this embodiment is made of CuSn0.15R420 copper alloy (surface electroplating treatment is determined according to requirements) and is electrically connected to the winding output wire (can be soldered or resistance welded). The winding in this embodiment is a single-layer wiring. In some embodiments, there may be one blade terminal, which is electrically connected to the output line of the first winding 41 or the second winding 42; in other embodiments, there may be two blade terminals, one of which is electrically connected to the output line of the first winding 41 and the other is electrically connected to the output line of the second winding 42.

[0064] refer to Figure 15-18In the embodiment of the utility model, a first protruding structure 621 and a second protruding structure 622 are respectively provided on both sides of the second connecting portion 62, and the base 1 is provided with a first card slot 11 matched with the first protruding structure 621, and a second card slot 12 matched with the second protruding structure 622; a connecting hole 623 is also provided on the second connecting portion 62, and a base 1 extension portion 13 is provided on the base 1 in a direction perpendicular to the base 1, and a hook 131 is provided at the end of the base 1 extension portion 13 for engaging with the connecting hole 623.

[0065] refer to Figure 15-16 , Figure 19-20 In the embodiment of the utility model, the bending portion includes a first bending structure 624 and a second bending structure 625, the first bending structure 624 and the second bending structure 625 are arranged perpendicular to the second connecting portion 62, the first bending structure 624 is fixedly connected to the first connecting portion 61, and the second bending structure 625 is fixedly connected to the second connecting portion 62. When the blade terminal 6 is connected to the base 1, the second bending structure 625 can fit the surface of the base 1, and the first bending structure 624 is higher than the second bending structure 625 and is parallel to the surface of the base 1.

[0066] refer to Figure 5 In the embodiment of the utility model, the bonding block 7 includes the first to fourth bonding blocks, the third magnetic core 23 is bonded to the first end of the first magnetic core 21 and the first end of the second magnetic core 22 through the first bonding block 71, the sixth magnetic core 26 is bonded to the first end of the fourth magnetic core 24 and the first end of the fifth magnetic core 25 through the second bonding block 72, the second end of the first magnetic core 21 and the second end of the fourth magnetic core 24 are bonded through the third bonding block 73, and the second end of the second magnetic core 22 and the second end of the fifth magnetic core 25 are bonded through the fourth bonding block 74; the first to fourth bonding blocks are structural parts made of epoxy resin silicone baking glue and cured. The epoxy resin-containing silicone baking adhesive has ideal bonding strength and stress resistance at high temperatures, allowing the device to have stable performance under high reliability requirements. In this embodiment, in addition to the above-mentioned bonding blocks, the fixed connection between the first to sixth magnetic cores 26 and the base 1, the fixed connection between the shielding copper sheet and the base 1, the fixed connection between the shielding copper sheet and the winding, the fixed connection between the terminal and the base 1, and other component connections are all achieved using a structural member (i.e., a fixed bonding block 7) made of epoxy resin-containing silicone baking adhesive and cured.

[0067] The specific structure of each component in this embodiment is as follows:

[0068] 1.Reference Figure 21-24 , the skeleton structure in this embodiment is as follows:

[0069] 1) The first baffle 313 provided on the first frame 31 and the second baffle 323 provided on the second frame 32 form multiple positions to avoid air and facilitate the glue to penetrate into the internal coil;

[0070] 2) The hollowed-out mesh holes in the first frame 31 and the second frame 32 can effectively prevent internal heat accumulation and facilitate glue penetration and heat dissipation system output;

[0071] 3) The first routing limiter 314 provided on the first frame 31 and the second routing limiter 324 provided on the second frame 32 facilitate the leading out of the starting line and the tail line at the fixed position;

[0072] 4) The first fixing portion 315 provided on the first frame 31 and the second fixing portion 325 provided on the second frame 32 are fixed in position in coordination with the winding inlet and outlet positions;

[0073] 5) The first limiting portion 311 and the second limiting portion 312 provided on the first frame 31, and the third limiting portion 321 and the fourth limiting portion 322 provided on the second frame 32 cooperate with the two side covers of the magnetic core (and the third magnetic core 23 and the sixth magnetic core 26) to limit the position;

[0074] 2. Introduction to core structure design:

[0075] refer to Figure 25-26 The magnetic core is composed of a third magnetic core 23 (I magnetic core) + a first magnetic core 21, a second magnetic core 22, a third magnetic core 23, a fourth magnetic core 24 (all of which are elliptical center column magnetic cores) + a sixth magnetic core 26 (I magnetic core), and the shape and size can be changed according to actual design requirements.

[0076] Advantages and characteristics of the combined magnetic core 1: The single body structure is simple and well formed, with the best manufacturing density and strength. The combined magnetic core using fixed bonding blocks has the following characteristics: The combined effect of splicing with epoxy resin silicone baking glue can ensure that the stress resistance effect is guaranteed in the AEC-Q200 series experiments, and can be further cut in the middle of the third magnetic core 23 or the sixth magnetic core 26 (the surface area of ​​the magnetic core increases and the core loss is further reduced).

[0077] 3.Reference Figure 15-Figure 20 , the blade terminal 6 and the base 1 are introduced:

[0078] The two sides of the blade terminal 6 are made into card slots to cooperate with the base 1 + the square-shaped connecting hole 623 is combined with the structural hook 131 of the base 1. The blade terminal 6 and the base 1 are flatly dragged to achieve a combined balance, and the operation is simple and effective. The first connecting part 61 of the blade terminal 6 is the electrical connection position with the wire (can be resistance welded), and the blade terminal 6 is plug-connected with the PCB to achieve electrical connection (convenient and reliable).

[0079] 4.Reference Fig.17 , Figure 27-Figure 29 , Base 1 structural design introduction:

[0080] 1) The protrusion 14 can also be used as an insulation protection distance in conjunction with the winding inlet and outlet wires;

[0081] 2) Ventilation hole 15: the client has a housing cavity. This product needs to be filled with glue through the cavity and the product needs to be placed in it. The air inside needs to be discharged through the vent hole 15 to achieve the glue filling rhythm and effect;

[0082] 3) The auxiliary part 16 can add auxiliary welding PIN to improve the fixing strength of the matching product;

[0083] 4) The two sides of the base 1 are designed with ribs (i.e., ribs 17) to ensure that the contour accuracy of the structural parts during the injection molding process is high;

[0084] 5) The base 1 is provided with a first positioning pin 181 and a second positioning pin 182 to ensure that the product is matched and positioned with the PCB board, thereby reducing the deviation of the activity tolerance;

[0085] 6) The extension 13 is a matching structure between the terminal structure and the base 1, so that the terminal base plate can be inserted and then placed to withdraw the PIN;

[0086] 7) The limiting structure 19 is used to limit the position of the base 1 and the shielding copper sheet, and the corresponding air holes are provided on the shielding copper sheet;

[0087] 8) A QR code label space is reserved in the middle of base 1 for easy traceability.

[0088] The process route of this embodiment is introduced as follows: the winding is wound into a wire package through the automatic winding equipment and the skeleton---the magnetic core combination is fixed with glue---the shielding copper sheet and the base 1 are fixed with glue---the terminal and the winding are electrically connected---the glue is fixed and baked (the glue is finally cured into a fixed bonding block)---electrical testing, appearance inspection---packaging and storage. Specifically, the first skeleton 31 and the second skeleton 32 are placed on the winding shaft and the corresponding wire is used to wind the first winding 41 and the second winding 42 into a combination, and then assembled and fixed by I magnetic core + elliptical middle column magnetic core + I magnetic core and glue. The cutting position of the magnetic core I magnetic core can be bonded and prepared in advance. The assembled product is then assembled with the shielding copper sheet and the base 1 by glue. The terminal and the winding input and output lines are connected correspondingly at the position of the base 1. The product is then fixed on the packaging jig for baking. After the baking glue is cured, the product is formed.

[0089] The beneficial effects of the embodiments of the present utility model are as follows:

[0090] The magnetic core of this embodiment is in block shape, and the size is simple, regular and uniform block and column shape. During the manufacturing process, the density of molding and sintering will be high and the corresponding strength will be better. The single structure of the magnetic core structure is simple and well molded, the manufacturing density is the best, and the strength is also the best, ensuring the reliability of the product.

[0091] The design of one layer of cable + structural parts can facilitate automatic winding. The rear end combination is positioned with the magnetic core and the base, and the limited position is convenient for assembly. The heat dissipation area after the overall glue filling effect is good. The laser QR code mark in the middle of the BASE is for traceability;

[0092] After the terminal structure and the base are installed, they reach the anti-retraction PIN, which can effectively prevent mistakes. The knife terminal effect is convenient for production and use;

[0093] The structural design and product appearance design process are simple, with very good consistency, convenient quality control and other reliable effects;

[0094] The designed products select corresponding heat dissipation conditions and materials according to actual needs to improve product competitiveness.

[0095] The existing technology is mostly based on two methods: independent resonant inductor, main transformer, and integration of resonant inductor and main transformer. The actual size and space occupied will be larger. The integrated leakage inductor of this design can effectively reduce the volume of magnetic parts and reduce the size of the end user. The design of wire wrapping around the magnetic core (the heat dissipation effect of the wire will be better) can make the current density of the wire larger, and the core will heat up (so high-frequency, high-temperature and low-loss magnetic core is selected). The product volume can be adjusted by water cooling on one side, two sides or three sides for heat dissipation.

[0096] 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 the absence of mutual contradiction, those skilled in the art 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 may be made herein without departing from the scope of protection of the patent application.

Claims

1. A vehicle-mounted transformer, characterized in that: include: A base, and first to sixth magnetic cores, first to second frames and first to second windings arranged on the base; The first magnetic core is arranged in parallel with the second magnetic core, the third magnetic core is arranged perpendicular to the first magnetic core and the second magnetic core, and is attached to the first end of the first magnetic core and the first end of the second magnetic core; the fourth magnetic core is arranged in parallel with the fifth magnetic core, the sixth magnetic core is arranged perpendicular to the fourth magnetic core and the fifth magnetic core, and is attached to the first end of the fourth magnetic core and the first end of the fifth magnetic core; the second end of the first magnetic core is attached to the second end of the fourth magnetic core, and the second end of the second magnetic core is attached to the second end of the fifth magnetic core; The first magnetic core and the fourth magnetic core are covered with a first frame, and the second magnetic core and the fifth magnetic core are covered with a second frame; The first winding is wound on the first frame, and the second winding is wound on the second frame.

2. The vehicle-mounted transformer according to claim 1, characterized in that: At least one of the third magnetic core and the sixth magnetic core includes a first magnetic core unit and a second magnetic core unit which are arranged in parallel and in close contact with each other.

3. The vehicle-mounted transformer according to claim 1, characterized in that: The first magnetic core, the second magnetic core, the fourth magnetic core, and the fifth magnetic core are elliptical center column magnetic cores, and the third magnetic core and the sixth magnetic core are I-piece magnetic cores.

4. The vehicle-mounted transformer according to claim 1, characterized in that: The two ends of the first skeleton extend outward to form a first limiting portion and a second limiting portion, respectively. The two ends of the second skeleton extend outward to form a third limiting portion and a fourth limiting portion, respectively. The first limiting portion and the third limiting portion are used to respectively limit the short sides of the third magnetic core and jointly limit a long side. The third limiting portion and the fourth limiting portion are used to respectively limit the short sides of the sixth magnetic core and jointly limit a long side.

5. The vehicle-mounted transformer according to claim 1, characterized in that: A shielding sheet is further arranged between the first frame, the second frame and the base. The first frame and the second frame are fixed to a first surface of the shielding sheet, and a second surface of the shielding sheet is arranged on the base.

6. The vehicle-mounted transformer according to claim 1, characterized in that: The base is also fixedly provided with one or two blade terminals on a surface away from the first to the second skeleton, and the blade terminal is used to make an electrical connection with the first winding or the second winding output line, and the blade terminal includes a first connecting portion and a second connecting portion arranged perpendicular to the first connecting portion, the first connecting portion and the second connecting portion are connected via a bending portion, the first connecting portion is used to make an electrical connection with the winding output line, and the second connecting portion is used to be fixedly connected to the base.

7. The vehicle-mounted transformer according to claim 6, characterized in that: A first protruding structure and a second protruding structure are respectively provided on both sides of the second connecting portion, and the base is provided with a first card slot cooperating with the first protruding structure, and a second card slot cooperating with the second protruding structure; a connecting hole is also provided on the second connecting portion, and a base extension portion is provided on the base in a direction perpendicular to the base, and a hook is provided at the end of the base extension portion to be engaged with the connecting hole.

8. The vehicle-mounted transformer according to claim 6, characterized in that: The bending portion includes a first bending structure and a second bending structure, the first bending structure and the second bending structure are arranged perpendicular to the second connecting portion, the first bending structure is fixedly connected to the first connecting portion, and the second bending structure is fixedly connected to the second connecting portion. When the blade terminal is connected to the base, the second bending structure can fit the surface of the base, and the first bending structure is higher than the second bending structure and is parallel to the surface of the base.

9. The vehicle-mounted transformer according to claim 1, characterized in that: The third magnetic core is bonded to the first end of the first magnetic core and the first end of the second magnetic core through a first bonding block, the sixth magnetic core is bonded to the first end of the fourth magnetic core and the first end of the fifth magnetic core through a second bonding block, the second end of the first magnetic core and the second end of the fourth magnetic core are bonded through a third bonding block, and the second end of the second magnetic core and the second end of the fifth magnetic core are bonded through a fourth bonding block; the first to fourth bonding blocks are structural parts made of epoxy resin silicone baking adhesive and cured.

10. The vehicle-mounted transformer according to claim 1, characterized in that: Grid holes are arranged on the surfaces of the first frame and the second frame.

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