Transformer structure

Abstract

The utility model discloses a transformer structure. The transformer structure comprises a magnetic core and a winding circuit, the magnetic core comprises a first magnetic plate, a second magnetic plate and at least one magnetic column unit, and the at least one magnetic column unit is located between the first magnetic plate and the second magnetic plate; each magnetic column unit comprises a first magnetic column, a second magnetic column, a third magnetic column and a fourth magnetic column; the connecting line between the first magnetic column and the second magnetic column intersects with the connecting line between the third magnetic column and the fourth magnetic column. The number of turns of winding circuits of the first magnetic column and the second magnetic column is the same, and the winding directions are opposite; and the third magnetic column and the fourth magnetic column are not provided with winding circuits. According to the transformer, the occupied area can be reduced, the power density can be improved, the magnetic flux density can be reduced, and the magnetic core loss can be reduced.

Description

Technical Field

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

[0002] Existing photovoltaic micro-inverters use multiple independent transformers, resulting in a relatively large total board area and difficulty in meeting the increasing power density requirements in the market. Figure 1 It is a schematic structural diagram of a transformer in the prior art. The flyback interleaved parallel topology in a photovoltaic micro-inverter is an efficient circuit structure, especially suitable for photovoltaic grid-connected micro-inverters. Figure 2 It is a schematic topology diagram of a photovoltaic grid-connected micro-inverter. The flyback interleaved parallel topology is usually composed of multiple flyback converters connected in parallel. Each flyback converter works independently but interleaves with each other to achieve higher power output and better performance. The unintegrated magnetic core has a large board area. If an un-decoupled integrated magnetic core is used, although the power density is improved, the current will be uneven due to magnetic field coupling between multi-phase circuits, and the total magnetic flux of the integrated magnetic core becomes larger, resulting in larger magnetic core losses. Summary of the Utility Model

[0003] The utility model provides a transformer structure, which can reduce the board area, improve the power density, and at the same time can reduce the magnetic flux density and magnetic core losses.

[0004] According to one aspect of the utility model, a transformer structure is provided, including:

[0005] A magnetic core and a winding circuit;

[0006] The magnetic core includes a first magnetic plate, a second magnetic plate and at least one magnetic column unit. At least one magnetic column unit is located between the first magnetic plate and the second magnetic plate; each magnetic column unit includes a first magnetic column, a second magnetic column, a third magnetic column and a fourth magnetic column; the connection line between the first magnetic column and the second magnetic column intersects with the connection line between the third magnetic column and the fourth magnetic column; the first magnetic column and the second magnetic column are provided with winding circuits, and the number of turns of the winding circuits of the first magnetic column and the second magnetic column is the same, and the winding directions are opposite; the third magnetic column and the fourth magnetic column are not provided with winding circuits.

[0007] Optionally, both the first magnetic column and the second magnetic column are in contact with the first magnetic plate; there is an air gap between the first magnetic column and the second magnetic plate, and there is an air gap between the second magnetic column and the second magnetic plate.

[0008] Optionally, along the direction from the first magnetic plate to the second magnetic plate, the size of the air gap between the first magnetic column and the second magnetic plate is the same as the size of the air gap between the second magnetic column and the second magnetic plate.

[0009] Optionally, both the third magnetic column and the fourth magnetic column are in contact with the first magnetic plate, and both the third magnetic column and the fourth magnetic column are in contact with the second magnetic plate.

[0010] Optionally, the area of the vertical projection of the first magnetic post on the first magnetic plate is the same as the area of the vertical projection of the second magnetic post on the first magnetic plate;

[0011] The area of the vertical projection of the third magnetic post on the first magnetic plate is the same as the area of the vertical projection of the fourth magnetic post on the first magnetic plate.

[0012] Optionally, the shape of the vertical projection of the first magnetic post on the first magnetic plate includes a square or a circle;

[0013] The shape of the vertical projection of the third magnetic post on the first magnetic plate includes a square or a circle.

[0014] Optionally, the first magnetic plate and the second magnetic plate have the same shape and size; the shapes of the first magnetic plate and the second magnetic plate include a square or a circle.

[0015] Optionally, the winding circuit includes a primary winding and a secondary winding; the primary winding is located on the side of the secondary winding away from the first magnetic plate.

[0016] Optionally, the winding circuit is a copper winding circuit.

[0017] Optionally, the length range of each magnetic post unit is ≤ 40 mm;

[0018] The width range of each magnetic post unit is ≤ 40 mm;

[0019] The thickness range of each magnetic post unit is ≤ 15 mm.

[0020] The transformer structure in the technical solution of the present utility model includes: a magnetic core and a winding circuit; the magnetic core includes a first magnetic plate, a second magnetic plate and at least one magnetic post unit, and at least one magnetic post unit is located between the first magnetic plate and the second magnetic plate; each magnetic post unit includes a first magnetic post, a second magnetic post, a third magnetic post and a fourth magnetic post; the connection line between the first magnetic post and the second magnetic post intersects with the connection line between the third magnetic post and the fourth magnetic post; a winding circuit is arranged between the first magnetic post and the second magnetic post, the number of turns of the winding circuits of the first magnetic post and the second magnetic post is the same, and the winding directions are opposite; no winding circuit is arranged between the third magnetic post and the fourth magnetic post. The winding directions of the winding circuits of the first magnetic post and the second magnetic post are opposite, so that the magnetic fluxes can cancel each other out, reducing losses; and the transformer structure of the present utility model can integrate four magnetic posts, which is equivalent to the volume of the existing single-magnetic-post transformer, reducing the board area occupied by the magnetic core and improving the power density at the same time.

[0021] It should be understood that the content described in this part is not intended to identify the key or important features of the embodiments of the present utility model, nor is it used to limit the scope of the present utility model. Other features of the present utility model will become easily understood through the following description. Description of the Drawings

[0022] To more clearly illustrate the technical solutions in the embodiments of the present utility model, the following will briefly introduce the drawings required for description in the embodiments. Obviously, the drawings described below are only some embodiments of the present utility model. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0023] Figure 1 It is a schematic structural diagram of a transformer in the prior art.

[0024] Figure 2 It is a schematic topological structure diagram of a photovoltaic grid-connected micro-inverter.

[0025] Figure 3 It is a schematic structural diagram of a transformer provided by an embodiment of the present utility model.

[0026] Figure 4 It is a top view of the structure of a transformer provided by an embodiment of the present utility model.

[0027] Figure 5 It is a side view of the structure of a transformer provided by an embodiment of the present utility model.

[0028] Figure 6 It is another side view of the structure of a transformer provided by an embodiment of the present utility model.

[0029] Figure 7 It is another top view of the structure of a transformer provided by an embodiment of the present utility model. Detailed implementation manners

[0030] In order to enable those skilled in the art to better understand the solutions of the present utility model, the following will clearly and completely describe the technical solutions in the embodiments of the present utility model in conjunction with the drawings in the embodiments of the present utility model. Obviously, the described embodiments are only some of the embodiments of the present utility model, rather than all of them. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present utility model.

[0031] It should be noted that the terms "first", "second", etc. in the present utility model are used to distinguish similar objects, and do not necessarily need to be used to describe a specific order or sequence. It should be understood that the data used in this way can be interchanged under appropriate circumstances, so that the embodiments of the present utility model described herein can be implemented in an order other than those illustrated or described herein. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, system, product or device including a series of steps or units does not necessarily have to be limited to those steps or units clearly listed, but may include other steps or units not clearly listed or inherent to these processes, methods, products or devices.

[0032] An embodiment of the present utility model provides a transformer structure. Figure 3 It is a schematic structural diagram of a transformer provided by an embodiment of the present utility model. Figure 4 It is a top view of the structure of a transformer provided by an embodiment of the present utility model. Figure 5 It is a side view of the structure of a transformer provided by an embodiment of the present utility model. Refer to Figures 3 - 5 , the transformer structure includes:

[0033] A magnetic core 10 and a winding circuit 20; the magnetic core 10 includes a first magnetic plate 11, a second magnetic plate 12 and at least one magnetic column unit 13, and at least one magnetic column unit 13 is located between the first magnetic plate 11 and the second magnetic plate 12; each magnetic column unit 13 includes a first magnetic column T1, a second magnetic column T2, a third magnetic column T3 and a fourth magnetic column T4; the connection line between the first magnetic column T1 and the second magnetic column T2 intersects the connection line between the third magnetic column T3 and the fourth magnetic column T4; the winding circuit 20 is arranged between the first magnetic column T1 and the second magnetic column T2, and the number of turns of the winding circuit 20 between the first magnetic column T1 and the second magnetic column T2 is the same, and the winding directions are opposite; the winding circuit 20 is not arranged between the third magnetic column T3 and the fourth magnetic column T4.

[0034] Wherein, Figures 3 - 5Exemplarily, the structure of 13 of a magnetic column unit is shown; the magnetic core 10 is made of magnetic material, and the material of the winding circuit 20 can be copper foil material; the winding circuit 20 includes a primary winding 21 and a secondary winding 22. The primary winding 21 refers to the input side of the voltage, and the secondary winding 22 refers to the output side of the voltage after being transformed by the transformer. If the transformer structure is to transform from low voltage to high voltage, the number of turns of the primary winding 21 is greater than that of the secondary winding 22. Each magnetic column unit 13 includes a first magnetic column T1, a second magnetic column T2, a third magnetic column T3, and a fourth magnetic column T4. In the present utility model, the volume of each integrated magnetic column unit is approximately 40mm * 40mm * 15mm. The transformer structure of the present utility model can integrate four magnetic columns, which is equivalent to the volume of the existing single-magnetic-column transformer, reducing the board area occupied by the magnetic core and improving the power density at the same time. The connection line between the first magnetic column T1 and the second magnetic column T2 intersects with the connection line between the third magnetic column T3 and the fourth magnetic column T4. The first magnetic column T1 and the second magnetic column T2 are arranged diagonally, and the third magnetic column T3 and the fourth magnetic column T4 are arranged diagonally. The number of turns of the winding circuit 20 of the first magnetic column T1 and the second magnetic column T2 is the same, and the winding directions are opposite. Exemplarily, if the winding direction of the first magnetic column T1 can be clockwise winding, then the winding direction of the second magnetic column T2 is counterclockwise winding. The number of turns of the winding circuit 20 of the first magnetic column T1 and the second magnetic column T2 is the same, and the winding directions are opposite, which can make the magnetic flux distribution of the wound transformer uniform. The winding directions of the winding circuit 20 of the first magnetic column T1 and the second magnetic column T2 are opposite, and the magnetic fluxes can cancel each other out, reducing the loss.

[0035] The transformer structure in the technical solution of the present utility model includes: a magnetic core 10 and a winding circuit 20; the magnetic core 10 includes a first magnetic plate 11, a second magnetic plate 12, and at least one magnetic column unit 13. At least one magnetic column unit 13 is located between the first magnetic plate 11 and the second magnetic plate 12; each magnetic column unit 13 includes a first magnetic column T1, a second magnetic column T2, a third magnetic column T3, and a fourth magnetic column T4; the connection line between the first magnetic column T1 and the second magnetic column T2 intersects with the connection line between the third magnetic column T3 and the fourth magnetic column T4; the first magnetic column T1 and the second magnetic column T2 are provided with a winding circuit 20, and the number of turns of the winding circuit 20 of the first magnetic column T1 and the second magnetic column T2 is the same, and the winding directions are opposite; the third magnetic column T3 and the fourth magnetic column T4 are not provided with a winding circuit 20. The winding directions of the winding circuit 20 of the first magnetic column T1 and the second magnetic column T2 are opposite, and the magnetic fluxes can cancel each other out, reducing the loss; and the transformer structure of the present utility model can integrate four magnetic columns, which is equivalent to the volume of the existing single-magnetic-column transformer, reducing the board area occupied by the magnetic core and improving the power density at the same time.

[0036] Optionally, Figure 6 is a side view of the structure of another transformer provided by an embodiment of the present utility model. Refer to Figure 6, the first magnetic post T1 and the second magnetic post T2 are both in contact with the first magnetic plate 11; there is an air gap 30 between the first magnetic post T1 and the second magnetic plate 12, and there is an air gap 30 between the second magnetic post T2 and the second magnetic plate 12.

[0037] Among them, the air gap 30 is provided between both the first magnetic post T1 and the second magnetic post T2 and the second magnetic plate 12. The air gap 30 can store and transfer energy in the circuit. The air gap 30 can reduce the magnetic permeability and avoid the occurrence of magnetic saturation phenomenon, so as to better control the inductance.

[0038] Optionally, referring to Figure 6 , along the direction from the first magnetic plate 11 to the second magnetic plate 12, the size of the air gap 30 between the first magnetic post T1 and the second magnetic plate 12 is the same as the size of the air gap 30 between the second magnetic post T2 and the second magnetic plate 12.

[0039] Among them, along the direction from the first magnetic plate 11 to the second magnetic plate 12, the size of the air gap 30 between the first magnetic post T1 and the second magnetic plate 12 is the same as the size of the air gap 30 between the second magnetic post T2 and the second magnetic plate 12, which can achieve mutual decoupling between the first magnetic post T1 and the second magnetic post T2, reduce the magnetic flux density, and reduce the magnetic loss.

[0040] Optionally, referring to Figure 6 , the third magnetic post T3 and the fourth magnetic post T4 are both in contact with the first magnetic plate 11, and the third magnetic post T3 and the fourth magnetic post T4 are both in contact with the second magnetic plate 12.

[0041] Among them, no winding circuit 20 is provided between the third magnetic post T3 and the fourth magnetic post T4. The third magnetic post T3 and the fourth magnetic post T4 are both in contact with the first magnetic plate 11, and the third magnetic post T3 and the fourth magnetic post T4 are both in contact with the second magnetic plate 12. There is no air gap, which can provide a low magnetic resistance loop to short-circuit the mutually coupled magnetic flux between the first magnetic post T1 and the second magnetic post T2, thereby reducing the magnetic flux density and reducing the core loss.

[0042] Optionally, referring to Figures 3 - 6 , the area of the vertical projection of the first magnetic post T1 on the first magnetic plate 11 is the same as the area of the vertical projection of the second magnetic post T2 on the first magnetic plate 11; the area of the vertical projection of the third magnetic post T3 on the first magnetic plate 11 is the same as the area of the vertical projection of the fourth magnetic post T4 on the first magnetic plate 11.

[0043] Among them, the area of the vertical projection of the first magnetic column T1 on the first magnetic plate 11 is the same as the area of the vertical projection of the second magnetic column T2 on the first magnetic plate 11; the area of the vertical projection of the third magnetic column T3 on the first magnetic plate 11 is the same as the area of the vertical projection of the fourth magnetic column T4 on the first magnetic plate 11, which can ensure that the magnetic fluxes of the first magnetic column T1 and the second magnetic column T2 are the same, and the number of turns of the winding line 20 of the first magnetic column T1 and the second magnetic column T2 is the same, and the winding directions are opposite, so that the same magnetic fluxes can cancel each other out and reduce losses.

[0044] Optionally, referring to Figures 3 - 6 , the shape of the vertical projection of the first magnetic column T1 on the first magnetic plate includes a square or a circle; the shape of the vertical projection of the third magnetic column T3 on the first magnetic plate includes a square or a circle.

[0045] Among them, Figures 3 - 6 the shape of the vertical projection of the first magnetic column T1 on the first magnetic plate in is a circle; the shape of the vertical projection of the third magnetic column T3 on the first magnetic plate is a circle, the area of the vertical projection of the first magnetic column T1 and the second magnetic column T2 on the first magnetic plate is the same; the area of the vertical projection of the third magnetic column T3 and the fourth magnetic column T4 on the first magnetic plate is the same; the area of the vertical projection of the first magnetic column T1 and the third magnetic column T3 on the first magnetic plate can be the same or different, and both can achieve the effect of reducing the magnetic flux density and reducing the core loss, and the integrated transformer can reduce the board area occupied by the core and improve the power density.

[0046] Optionally, referring to Figure 6 , the first magnetic plate 11 and the second magnetic plate 12 have the same shape and size; the shapes of the first magnetic plate 11 and the second magnetic plate 12 include a square or a circle.

[0047] Among them, the first magnetic plate 11 and the second magnetic plate 12 can be symmetrically arranged, and the magnetic column unit 13 is located between the first magnetic plate 11 and the second magnetic plate 12; the first magnetic plate 11 and the second magnetic plate 12 have the same shape and size; the shapes of the first magnetic plate 11 and the second magnetic plate 12 include a square or a circle. The present invention does not specifically limit the shapes of the first magnetic plate 11 and the second magnetic plate 12, and can be set according to actual needs.

[0048] Optionally, referring to Figure 5 and Figure 6 , the winding line 20 includes a primary winding 21 and a secondary winding 22; the primary winding 21 is located on the side of the secondary winding 22 away from the first magnetic plate 11.

[0049] Among them, the primary side winding 21 refers to the input side of the voltage, and the secondary side winding 22 refers to the output side of the voltage after being transformed by the transformer. If the transformer structure is transformed from low voltage to high voltage, the number of turns of the primary side winding 21 is greater than that of the secondary side winding 22. Therefore, in the direction from the first magnetic plate 11 to the second magnetic plate 12, the thickness of the primary side winding 21 is greater than that of the secondary side winding 22.

[0050] Optionally, the winding circuit is a copper winding circuit.

[0051] Among them, the copper winding circuit has a lower cost and a mature process.

[0052] Optionally, the length range of each magnetic column unit is ≤ 40 mm; the width range of each magnetic column unit is ≤ 40 mm; the thickness range of each magnetic column unit is ≤ 15 mm.

[0053] Among them, when the transformer structure only includes one magnetic column unit, the maximum integrated structure volume of the transformer is 40 mm * 40 mm * 15 mm. The volume of the transformer in the present invention is the same as that of the transformer with only one magnetic column in the prior art. Therefore, the transformer in the present invention integrates at least four magnetic columns and can perform multi-channel decoupled magnetic cores, which can improve the power density of the transformer. Figure 7 It is a top view of the structure of another transformer provided by the embodiment of the present invention. Refer to Figure 7 , Figure 7 The transformer structure in is a rectangular array type transformer structure including a plurality of magnetic column units 13.

[0054] It should be understood that various forms of the processes shown above can be used, and the steps can be reordered, added or deleted. For example, the steps described in the present invention can be executed in parallel, sequentially or in a different order, as long as the desired results of the technical solution of the present invention can be achieved. This is not limited herein.

[0055] The above specific embodiments do not constitute a limitation to the protection scope of the present invention. Those skilled in the art should understand that various modifications, combinations, sub-combinations and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions and improvements made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A transformer structure, characterized in that: include: Magnetic core and winding circuits; The magnetic core includes a first magnetic plate, a second magnetic plate and at least one magnetic column unit, and the at least one magnetic column unit is located between the first magnetic plate and the second magnetic plate; each of the magnetic column units includes a first magnetic column, a second magnetic column, a third magnetic column and a fourth magnetic column; the connection line between the first magnetic column and the second magnetic column and the connection line between the third magnetic column and the fourth magnetic column intersect each other; the first magnetic column and the second magnetic column are provided with a winding line, the number of turns of the winding line of the first magnetic column and the second magnetic column are the same, and the winding directions are opposite; the third magnetic column and the fourth magnetic column are not provided with a winding line.

2. The transformer structure according to claim 1, characterized in that: The first magnetic column and the second magnetic column are both in contact with the first magnetic plate; there is an air gap between the first magnetic column and the second magnetic plate, and there is an air gap between the second magnetic column and the second magnetic plate.

3. The transformer structure according to claim 2, characterized in that: Along the direction from the first magnetic plate to the second magnetic plate, the size of the air gap between the first magnetic column and the second magnetic plate is the same as the size of the air gap between the second magnetic column and the second magnetic plate.

4. The transformer structure according to claim 1, characterized in that: The third magnetic column and the fourth magnetic column are both in contact with the first magnetic plate, and the third magnetic column and the fourth magnetic column are both in contact with the second magnetic plate.

5. The transformer structure according to claim 1, characterized in that: The area of ​​the vertical projection of the first magnetic column on the first magnetic plate is the same as the area of ​​the vertical projection of the second magnetic column on the first magnetic plate; An area of ​​a vertical projection of the third magnetic column on the first magnetic plate is the same as an area of ​​a vertical projection of the fourth magnetic column on the first magnetic plate.

6. The transformer structure according to claim 5, characterized in that: The vertical projection shape of the first magnetic column on the first magnetic plate includes a square or a circle; The vertical projection shape of the third magnetic column on the first magnetic plate includes a square or a circle.

7. The transformer structure according to claim 1, characterized in that: The first magnetic plate and the second magnetic plate have the same shape and size; the first magnetic plate and the second magnetic plate have a square or a circle shape.

8. The transformer structure according to claim 1, characterized in that: The winding circuit includes a primary winding and a secondary winding; the primary winding is located on a side of the secondary winding away from the first magnetic plate.

9. The transformer structure according to claim 1, characterized in that: The winding line is a copper winding line.

10. The transformer structure according to claim 1, characterized in that: The length of each magnetic column unit is ≤40 mm; The width of each magnetic column unit is ≤40 mm; The thickness of each magnetic column unit is within a range of ≤15 mm.

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