Magnetic core structure and magnetic device
By re-stitching the core module and setting up insulating gaskets, a new core structure is formed, which solves the problem that existing magnetic devices are difficult to improve power density in a limited space, and achieves higher power density and better heat dissipation effects.
Patent Information
- Application Number
- CN202421485068.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-06-26
- Publication Date
- 2025-05-09
- Estimated Expiration
- 2034-06-26
AI Technical Summary
When existing magnetic devices meet the demand for high power density, it is difficult to effectively improve power density in a limited space, and the heat dissipation and loss problems are relatively prominent.
A new core structure is formed by re-stitching the multiple core modules in their original position in the complete core and insulating gaskets are provided on the splicing surfaces between the multiple core modules. This structure increases the surface area of the core, reduces high-frequency eddy current losses, and optimizes the heat dissipation effect through the distribution of internal air gaps.
It is realized that while keeping the core volume unchanged, the power density of magnetic devices is improved, the loss and heat dissipation problems are reduced, and the utilization rate of magnetic core is improved.
Smart Images
Figure CN222851202U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of power conversion, in particular to a magnetic core structure and a magnetic device. Background Art
[0002] With the continuous development of electric vehicle technology, the power density of the power modules inside electric vehicles is getting higher and higher. Correspondingly, the power density requirements for the magnetic devices inside the power modules are also getting higher and higher.
[0003] Magnetic devices usually refer to power devices formed by coils wound around magnetic cores, such as inductors or transformers. In order to meet the requirements of high power density, the volume and wire diameter of magnetic devices need to be increased, but the total volume of the power module needs to remain unchanged. Therefore, higher requirements are placed on the design of magnetic devices so that they can improve power density and meet design requirements within a limited space. Utility Model Content
[0004] The embodiments of the utility model provide a magnetic core structure and a magnetic device to improve the power density of the magnetic device.
[0005] In a first aspect, an embodiment of the utility model provides a magnetic core structure, comprising: a plurality of magnetic core modules; the plurality of magnetic core modules are combined and spliced to form a complete magnetic core;
[0006] The plurality of magnetic core modules are spliced according to the original position layout in the complete magnetic core, and gaskets are provided on the splicing surfaces between the plurality of magnetic core modules.
[0007] In a possible implementation, the plurality of magnetic core modules are obtained by cutting a complete magnetic core along a horizontal center axis and / or a vertical center axis.
[0008] In a possible implementation, a gasket is provided on each joint surface between the plurality of magnetic core modules; the gasket is made of insulating material.
[0009] In a possible implementation, the thickness of the gasket is any value between 0.1 mm and 0.3 mm.
[0010] In a second aspect, an embodiment of the utility model provides a magnetic device, comprising: a magnetic core structure as described in any one of the first aspects, wherein the magnetic device comprises a transformer and an inductor.
[0011] In a possible implementation, the magnetic device is a transformer, and the transformer further includes a primary coil and a secondary coil; two magnetic core structures constitute a transformer magnetic core;
[0012] The primary coil and the secondary coil are wound on the middle column of the transformer magnetic core.
[0013] In a possible implementation manner, the primary coil and the secondary coil are both wound in a single layer.
[0014] In a possible implementation, the primary coil is wound on a middle column of the transformer core;
[0015] The secondary coil is wound on the outer surface of the primary coil in a stacked manner.
[0016] In a possible implementation, the primary coil is wound at preset positions on both sides of the middle column of the transformer core, and the secondary coil is wound at a preset position in the middle of the middle column of the transformer core;
[0017] Alternatively, the secondary coil is wound at preset positions on both sides of the middle column of the transformer core, and the primary coil is wound at a preset position in the middle of the middle column of the transformer core.
[0018] In a possible implementation, a ventilation gap is provided between the inner surfaces of the primary coil and the secondary coil and the outer surface of the middle column of the transformer core.
[0019] The utility model embodiment provides a magnetic core structure and a magnetic device, which is obtained by re-joining a plurality of magnetic core modules according to their original position layout in a complete magnetic core, and setting gaskets on the joint surfaces between the plurality of magnetic core modules. Among them, by combining and splicing a plurality of magnetic core modules and setting gaskets between the joint surfaces, the surface area of the magnetic core structure can be effectively increased, thereby reducing the high-frequency eddy current loss on the surface of the magnetic core structure, and the re-joined magnetic core structure is equivalent to doping an air gap inside the complete magnetic core structure, which can make the magnetic core structure heat evenly, and at the same time effectively increase the effective cross-sectional area of the magnetic core, improve the utilization rate of the magnetic core, and thus reduce the loss. In addition, the magnetic core structure provided by the present application will not increase the volume of the magnetic core structure, and can ultimately achieve the technical effect of improving the power density on the basis of keeping the volume of the magnetic core unchanged. BRIEF DESCRIPTION OF THE DRAWINGS
[0020] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.
[0021] Figure 1 It is a structural schematic diagram of a magnetic core structure provided by an embodiment of the utility model;
[0022] Figure 2 It is a structural schematic diagram of a transformer magnetic core provided by an embodiment of the utility model;
[0023] Figure 3 It is a structural schematic diagram of a transformer provided by an embodiment of the utility model;
[0024] Figure 4 It is a schematic diagram of the winding of the primary and secondary coils provided in one embodiment of the utility model;
[0025] Figure 5 It is a schematic diagram of the winding of the primary and secondary coils provided in another embodiment of the utility model;
[0026] Figure 6 It is a schematic diagram of winding of primary and secondary coils provided by another embodiment of the utility model;
[0027] Figure 7 It is a left view of a transformer provided in one embodiment of the utility model. DETAILED DESCRIPTION
[0028] In order to enable people in the technical field to better understand the present solution, the technical solution in the embodiment of the present solution will be clearly described below in conjunction with the drawings in the embodiment of the present solution. Obviously, the described embodiment is an embodiment of a part of the present solution, not all of the embodiments. Based on the embodiments in the present solution, all other embodiments obtained by ordinary technicians in the field without creative work should fall within the scope of protection of the present solution.
[0029] The term "including" and any other variations in the specification and claims of this solution and the above drawings mean "including but not limited to", and is intended to cover non-exclusive inclusions and is not limited to the examples listed in the text. In addition, the terms "first" and "second" are used to distinguish different objects, not to describe a specific order.
[0030] As users' demands for the power density of power modules continue to increase, the power density requirements for magnetic devices such as inductors and transformers inside power modules are also getting higher and higher. However, the total volume of the power module needs to remain unchanged. Therefore, higher requirements are placed on the design of magnetic devices to improve the power density within a limited space.
[0031] If the power density is to be improved, the fundamental problem that leads to low power density needs to be solved, that is, reducing losses and optimizing heat dissipation structures. In order to reduce power losses and optimize heat dissipation structures to improve the power density of magnetic devices, in the implementation of the present application, multiple core modules are re-spliced according to their original position layout in a complete core, and gaskets are arranged on the splicing surfaces between multiple core modules to obtain a core structure. Among them, splicing multiple core modules and arranging gaskets between the splicing surfaces can effectively increase the surface area of the core structure, thereby reducing the high-frequency eddy current loss on the surface of the core structure, and the spliced core structure is equivalent to doping air gaps inside the complete core structure, which can make the core structure heat evenly, and at the same time effectively increase the effective cross-sectional area of the core, improve the utilization rate of the core, and thus reduce losses. In addition, the core structure provided by the present application will not increase the volume of the core structure, and can ultimately achieve the technical effect of improving power density on the basis of keeping the core volume unchanged.
[0032] The following is a detailed description of the implementation of the present invention in conjunction with the specific drawings:
[0033] Figure 1 This is a schematic diagram of a magnetic core structure provided by an embodiment of the utility model. Figure 1 The magnetic core structure includes: a plurality of magnetic core modules 11; a plurality of magnetic core modules are combined and spliced to form a complete magnetic core;
[0034] The multiple magnetic core modules are spliced according to the original position layout in the complete magnetic core, and gaskets 12 are provided on the splicing surfaces between the multiple magnetic core modules.
[0035] In an embodiment of the utility model, a complete magnetic core can be cut to obtain a plurality of corresponding magnetic core modules. A plurality of magnetic core modules can also be directly obtained by mold opening processing. Here, a plurality of magnetic core modules can be combined and spliced to form a complete magnetic core. A magnetic core structure is obtained by re-splicing a plurality of magnetic core modules according to their original position layout in a complete magnetic core, and arranging gaskets on the splicing surfaces between the plurality of magnetic core modules. Here, the area of the gasket can be consistent with the area of the splicing surface.
[0036] It should be noted that Figure 1 As an exemplary figure, the PQ core is taken as an example to show the structure diagram of the reassembled core structure, but this does not serve as a specific limitation on the core structure. Users can select a suitable core to cut and reassemble according to actual conditions to obtain a core structure.
[0037] The embodiment of the utility model adopts a mode of combining and splicing multiple magnetic core modules, and sets gaskets on the splicing surfaces between the multiple magnetic core modules, which can effectively increase the surface area of the magnetic core. The increase in the surface area of the magnetic core can effectively reduce the high-frequency eddy current loss on the surface of the magnetic core. In addition, gaskets are set between multiple magnetic core modules, and the magnetic core structure obtained by re-splicing is equivalent to doping air gaps inside the complete magnetic core, which can not only make the magnetic core structure heat evenly and optimize the heat dissipation structure, but also increase the effective cross-sectional area of the magnetic core, improve the utilization rate of the magnetic core, and thus reduce losses. In other words, the magnetic core structure in which multiple magnetic core modules are spliced according to the original position layout and gaskets are set on the splicing surface can not only optimize the heat dissipation structure, but also reduce losses, and finally achieve the technical effect of improving power density.
[0038] In some embodiments, a plurality of magnetic core modules may be obtained by cutting a complete magnetic core along a horizontal center axis and / or a vertical center axis.
[0039] See also Figure 1 ,exist Figure 1 In the illustrated perspective, in the embodiment of the utility model, the complete magnetic core can be cut along the horizontal center axis 13 and / or the vertical center axis 14 to obtain a plurality of magnetic core modules 11 .
[0040] In some embodiments, a gasket is provided on each joint surface between the plurality of magnetic core modules; the gasket is made of insulating material.
[0041] In some embodiments, the thickness of the gasket may be any value between 0.1 mm and 0.3 mm.
[0042] In the embodiment of the utility model, the gasket can be an epoxy gasket. The epoxy gasket is an insulating material and will not affect the magnetic field inside the magnetic core. It is equivalent to doping air gaps between multiple magnetic core modules, thereby optimizing the heat dissipation structure of the magnetic core structure and reducing the loss of the magnetic core structure.
[0043] In some embodiments, multiple core modules can be directly arranged and spliced in their original positions in the complete core to obtain a core structure without the need for a gasket. However, it is understandable that the power density improvement effect of the core structure with a gasket is better than that of the core structure without a gasket. The user can decide whether to set a gasket based on the actual power density requirements.
[0044] The magnetic core structure can be applied to all magnetic devices such as transformers and inductors. Therefore, based on the magnetic core structure, the embodiment of the utility model further provides a magnetic device. The magnetic device includes the magnetic core structure. The magnetic core device in the embodiment of the utility model can include but is not limited to devices such as transformers and inductors.
[0045] In some embodiments, the magnetic device may be a transformer. The transformer core in the transformer is composed of two magnetic core structures. Figure 2 ,Usually, the two core structures can be used as a pair of cores and ,joined to form a transformer core.
[0046] It should be noted that Figure 2 The schematic diagram of the transformer core formed when the PQ core is used as the transformer core is shown as an exemplary figure. However, this does not serve as a specific limitation on the transformer core. Users can select a suitable transformer core according to actual conditions.
[0047] In the embodiment of the utility model, two PQ cores can be spliced to form a transformer core. A gasket can also be arranged on the splicing surface between the two PQ cores to optimize the heat dissipation structure of the transformer and improve the power density of the transformer.
[0048] See also Figure 3 The transformer further comprises: a primary coil 31 and a secondary coil 32. Here, two magnetic core structures constitute a transformer magnetic core 33.
[0049] The primary coil 31 and the secondary coil 32 are wound on the center column of the transformer core 33 .
[0050] Usually, the two core structures are used as a pair of cores to form a transformer core. The primary coil and the secondary coil are wound on the center column of the transformer core to form a transformer.
[0051] Here, the primary coil and the secondary coil may use SZS multi-strand parallel twisted Mylar wire, for example, 0.05*1300 twisted wire, so as to further reduce the high-frequency eddy current loss of the wire.
[0052] It should be noted that Figure 3 The schematic diagram of the transformer formed when the PQ core is used as the transformer core is shown only as an exemplary figure. However, this does not serve as a specific limitation on the transformer. The user can select a suitable transformer core according to actual conditions, and wind the primary coil and the secondary coil on the transformer core to form a transformer.
[0053] Conventional transformers usually need to increase the core window area and reduce the core window utilization rate to avoid the problem of primary and secondary coil burnout. The transformer core in the transformer provided by the embodiment of the utility model adopts a method of splicing and combining multiple core modules, which can evenly distribute the air gap inside the entire transformer core and make the transformer core heat evenly. At the same time, it can also greatly reduce the influence of scattered magnetism, thereby reducing the core window area, effectively improving the core window utilization rate, and preventing the problem of burnout.
[0054] In some embodiments, both the primary coil and the secondary coil are wound in a single layer.
[0055] In some embodiments, see Figure 4 The primary coil 31 is wound on the middle column of the transformer core; the secondary coil 32 is superimposed and wound on the outer surface of the primary coil 31.
[0056] In the embodiment of the utility model, the primary coil and the secondary coil are both wound in a single layer, and the secondary coil is wound on the outer surface of the primary coil in an overlapping manner, which can effectively reduce the distributed capacitance and thus reduce the high-frequency loss of the primary coil and the secondary coil.
[0057] In some embodiments, see Figure 5 The primary coil 31 is wound at the preset positions on both sides of the center column of the transformer core, and the secondary coil 32 is wound at the preset position in the middle of the center column of the transformer core.
[0058] In some embodiments, see Figure 6 The secondary coil 32 is wound at the preset positions on both sides of the center column of the transformer core, and the primary coil 31 is wound at the preset position in the middle of the center column of the transformer core.
[0059] In the embodiment of the utility model, it is considered that the superposition of the magnetic field between the primary and secondary layers and the excessive length of the magnetic field loop may cause excessive magnetic loss. In order to avoid the problem of excessive magnetic loss, the primary coil and the secondary coil in the embodiment of the utility model are both wound in a single layer, and the primary coil and the secondary coil are alternately wound at a preset position on the middle column of the transformer core, which can effectively reduce the superposition of the magnetic field between the primary and secondary layers, thereby reducing the magnetic loss. Moreover, the more times the primary and secondary coils are alternated, the smaller the magnetic loss. The user can determine the number of alternations and the alternation order of the primary and secondary coils according to the actual situation.
[0060] In some embodiments, see Figure 7 A ventilation gap 71 is set between the inner surfaces of the primary coil and the secondary coil and the outer surface of the center column of the transformer core.
[0061] In order to further optimize the heat dissipation structure of the transformer, the embodiment of the utility model sets a ventilation gap between the inner surface of the primary and secondary coils and the outer surface of the center column of the transformer core, so that the transformer core and the coil can be directly exposed to wind, and the primary and secondary coils are wound in a single layer, which can ensure that the coils are exposed to wind on both sides, thereby further enhancing the heat dissipation effect.
[0062] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims
1. A magnetic core structure, characterized in that: include: A plurality of magnetic core modules; the plurality of magnetic core modules are combined and spliced to form a complete magnetic core; The plurality of magnetic core modules are spliced according to the original position layout in the complete magnetic core, and gaskets are provided on the splicing surfaces between the plurality of magnetic core modules.
2. The magnetic core structure according to claim 1, characterized in that: The plurality of magnetic core modules are obtained by cutting a complete magnetic core along a horizontal central axis and / or a vertical central axis.
3. The magnetic core structure according to claim 1 or 2, characterized in that: A gasket is provided on each joint surface between the plurality of magnetic core modules; the gasket is made of insulating material.
4. The magnetic core structure according to claim 3, characterized in that: The thickness of the gasket is any value between 0.1 mm and 0.3 mm.
5. A magnetic device, characterized in that: The magnetic core structure comprises the magnetic core structure as described in any one of claims 1 to 4, wherein the magnetic device comprises a transformer and an inductor.
6. The magnetic device according to claim 5, characterized in that The magnetic device is a transformer, and the transformer also includes a primary coil and a secondary coil; two magnetic core structures constitute the transformer magnetic core; The primary coil and the secondary coil are wound on the middle column of the transformer magnetic core.
7. The magnetic device according to claim 6, characterized in that The primary coil and the secondary coil are both wound in a single layer.
8. The magnetic device according to claim 7, characterized in that The primary coil is wound on the middle column of the transformer core; The secondary coil is wound on the outer surface of the primary coil in a stacked manner.
9. The magnetic device according to claim 7, characterized in that: The primary coil is wound at preset positions on both sides of the middle column of the transformer core, and the secondary coil is wound at a preset position in the middle of the middle column of the transformer core; Alternatively, the secondary coil is wound at preset positions on both sides of the middle column of the transformer core, and the primary coil is wound at a preset position in the middle of the middle column of the transformer core.
10. The magnetic device according to claim 9, characterized in that A ventilation gap is arranged between the inner surfaces of the primary coil and the secondary coil and the outer surface of the middle column of the transformer magnetic core.