High-power transformer for new energy vehicle charging device

Abstract

The utility model relates to a high-power transformer for a new energy vehicle charging device. The transformer consists of a magnetic core assembly, a winding coil and a PCB (Printed Circuit Board), the magnetic core assembly is formed by oppositely inserting and combining two E-shaped magnetic cores which are symmetrical up and down; when the upper E-shaped magnetic core and the lower E-shaped magnetic core are combined in an inserted mode, an airflow heat dissipation channel penetrating through the whole magnetic core assembly is formed in the magnetic core assembly. The winding coil and the magnetic core assembly are combined together, and two ventilation channels are formed in the portions, exposed on the two sides of the magnetic core assembly, of the hollow coil. The utility model has the advantages of low loss, good heat dissipation effect, large current work resistance, and uniform, safe and reliable current distribution.

Description

Technical Field

[0001] The utility model relates to electronic transformer technology, in particular to a high-power transformer for a new energy vehicle charging device. Background Art

[0002] The prior art new energy vehicle charging device generally uses a high-frequency transformer, which is composed of a coil, a skeleton, and a ferrite core. In the actual use process, in addition to the heating and temperature rise caused by the resistance of the coil itself, the high-frequency transformer also heats the ferrite core. The alternating magnetic field generates an induced current in the ferrite core, which causes the ferrite core to heat up, thereby transferring the heat to the coil and increasing the coil temperature. If the heat is not dissipated in time, the coil may be damaged. In order to solve this problem, on March 15, 2017, China Utility Model Authorization Announcement No. CN206022065U disclosed a skeleton-free high-frequency transformer, including a core assembly and a winding coil. The core assembly is provided with a transversely arranged core shaft, and the winding coil is wound on it in layers along the axial direction of the core shaft. An insulating plate is fixed at the bottom of the core assembly, and several leads from the winding coil pass through the insulating plate and form terminals on the insulating plate. Although the technical solution eliminates the structure of the skeleton inside the high-frequency transformer, it can make use of the space of the skeleton, and the power of the high-frequency transformer per unit volume is higher. However, the transformer made in this way has insulation paper between the core and the winding, and between each layer of winding coils. The heat dissipation effect between the winding and the core is not ideal under high power and full load, the voltage resistance is not high, and there are certain safety hazards. Utility Model Content

[0003] In view of the technical problems existing in the prior art, the utility model proposes a high-power transformer for a new energy vehicle charging device, which has the effects of low loss, good heat dissipation, high current resistance, uniform current distribution, safety and reliability.

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

[0005] A high-power transformer for a new energy vehicle charging device is composed of a magnetic core assembly, a winding coil and a PCB board; the magnetic core assembly is composed of two symmetrical "E"-shaped magnetic cores that are inserted into each other; a circular hole is provided on the central column of each "E"-shaped magnetic core, which runs from the central column surface to the root of the magnetic core; when the upper and lower "E"-shaped magnetic cores are inserted into each other, an airflow heat dissipation channel that runs through the entire magnetic core assembly is formed on the magnetic core assembly; the winding coil is divided into a high-voltage winding and a low-voltage winding, both of which are wound with a film-wrapped wire having a self-adhesive layer wrapped around multiple strands of enameled wire; the high-voltage winding and the low-voltage winding are combined by overlapping winding to form a hollow coil with a middle long shape and arc-shaped ends, and the part of the hollow coil exposed on both sides of the magnetic core assembly together with the magnetic core assembly produces two ventilation ducts; the lead ends of the high-voltage winding and the low-voltage winding are respectively led out and welded to different pins of the PCB board.

[0006] Compared with the prior art, the magnetic core assembly of the utility model is a magnetic core material of manganese-nickel-zinc ferrite, which has the excellent performance of high frequency, high saturation, high resistivity, magnetic flux density and low magnetic loss. The temperature rise and loss above 80℃ and 120℃ are not significantly different from those at 25℃, which is particularly suitable for high-frequency transformers of high-power new energy vehicle charging devices; its magnetic core assembly has a circular hole channel shape structure that runs from the central cylindrical surface to the root of the magnetic core, which is convenient for airflow heat dissipation, greatly improving the heat dissipation performance of the magnetic core assembly, and can effectively reduce magnetic loss. The winding coil of the utility model is wound with a film-wrapped wire having a self-adhesive layer wrapped around multiple strands of enameled wire. The film-wrapped wire itself has the characteristics of high strength, high temperature resistance and uniform current distribution. In addition, the winding coil is made into a hollow coil shape with a long middle shape and arc-shaped ends, and the two ventilation ducts formed after the magnetic core assembly is assembled into a transformer, and the heat dissipation performance of the ventilation duct is greatly improved, which is more conducive to the heat dissipation of the film-wrapped wire under the condition of high current charging of new energy vehicles.

[0007] Therefore, the utility model has the effects of low loss, good heat dissipation effect, resistance to large current operation, uniform current distribution, and safety and reliability. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The utility model is further described in detail below in conjunction with the accompanying drawings and specific implementation methods.

[0009] Figure 1 It is a main schematic diagram of the utility model.

[0010] Figure 2 for Figure 1 AA cross-sectional view of .

[0011] Figure 3 It is a schematic diagram of the winding coil of the utility model.

[0012] The reference numerals are: 1 magnetic core assembly; 2 winding coil; 3 PCB pin board; 4 central column of the magnetic core; 5 root of the magnetic core; 5 circular hole; 7 magnetic gap; 8 ventilation duct. DETAILED DESCRIPTION

[0013] The utility model is further described below in conjunction with the accompanying drawings and embodiments.

[0014] See also Figure 1-Figure 3 A high-power transformer for a new energy vehicle charging device is composed of a magnetic core component 1, a winding coil 2 and a PCB pin board 3; the characteristics are as follows: the magnetic core component 1 is composed of two symmetrical "E"-shaped magnetic cores inserted and assembled; each "E"-shaped magnetic core has a circular hole 6 on the central column 4 that passes through the central cylindrical surface to the magnetic core root 5; when the upper and lower "E"-shaped magnetic cores are inserted and assembled, on the magnetic core component 1, The circular holes of the two "E" shaped magnetic cores 6 An airflow heat dissipation channel is formed that runs through the entire magnetic core component 1; the magnetic gap 7 of the upper and lower "E"-shaped magnetic cores is filled with glue; the winding coil 2 is divided into a high-voltage winding and a low-voltage winding, both of which are wound with a film-wrapped wire having a self-adhesive layer wrapped around multiple strands of enameled wire; the high-voltage winding and the low-voltage winding are combined by overlapping winding to form a hollow coil with a long middle shape and arc-shaped ends, and the hollow coil is combined with the magnetic core component 1 to form two ventilation ducts 8 on the exposed parts of the magnetic core component 1 on both sides; the lead ends of the high-voltage winding and the low-voltage winding are respectively led out and welded to different pins of the PCB pin board 3.

[0015] Although the embodiments of the present invention have been shown and described above, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A high-power transformer for a new energy vehicle charging device, comprising a magnetic core assembly (1), a winding coil (2) and a PCB pin board (3); characterized in that: The magnetic core assembly (1) is composed of two symmetrical "E"-shaped magnetic cores inserted in pairs; a circular hole (6) is provided on the central column (4) of each "E"-shaped magnetic core, which passes through the central column surface to the root of the magnetic core (5); when the upper and lower "E"-shaped magnetic cores are inserted in pairs, an airflow heat dissipation channel that runs through the entire magnetic core assembly (1) is formed on the magnetic core assembly (1); the winding coil (2) is divided into a high-voltage winding and a low-voltage winding, both of which are wound with a film-wrapped wire having a self-adhesive layer wrapped around a plurality of enameled wire strands; the high-voltage winding and the low-voltage winding are combined by overlapping winding to form a hollow coil with a long middle shape and circular arcs at both ends, and the hollow coil is combined with the magnetic core assembly (1) to form two ventilation ducts (8) on the exposed parts of the hollow coil on both sides of the magnetic core assembly (1); the lead ends of the high-voltage winding and the low-voltage winding are respectively led out and welded to different pins of the PCB pin board (3).

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