Annular multi-winding balanced leakage inductance high-frequency transformer
By designing an annular multi-winding structure and built-in leakage inductance value regulator in high-frequency transformers, and adjusting the leakage inductance value between windings using insulating leakage magnetic strips, the problems of winding leakage inductance imbalance and adjustment difficulties are solved, and efficient and flexible transformer design is achieved.
Patent Information
- Application Number
- CN202422156747.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-03
- Publication Date
- 2025-06-13
- Estimated Expiration
- 2034-09-03
AI Technical Summary
In design and application, existing high-frequency transformers face the problems of winding leakage inductance imbalance and adjustment difficulties. It is difficult for traditional structures to adjust the leakage inductance value through external cores, and the increased core will affect the space efficiency and loss of the transformer.
A ring-shaped multi-winding balanced leakage inductance high-frequency transformer is designed, and a built-in leakage inductance value regulator is used to accurately adjust the leakage inductance value between each winding through the adjustment of the size of the insulated leakage magnetic sheet.
The adjustability of the leakage inductance value between the windings of each transformer is achieved, which improves the performance adjustment accuracy and flexibility of the transformer, while reducing space occupation and loss.
Smart Images
Figure CN222980280U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of transformers, and particularly relates to an annular multi-winding balanced leakage inductance high-frequency transformer. Background Art
[0002] With the continuous development of power electronics technology, high-frequency transformers, as key components for voltage conversion and electrical isolation in power electronic converters, are becoming increasingly important. However, current high-frequency transformers face many challenges in design and application. On the one hand, due to the lack of regularity in winding arrangement, there are differences in the coupling between windings, resulting in unbalanced leakage inductance. In practical applications, balanced leakage inductance between windings is often required to ensure the stable operation and high efficiency of power electronic converters. However, the irregularity of winding arrangement makes it quite difficult to achieve this goal. On the other hand, it is also difficult to adjust the leakage inductance value between windings when a multi-winding transformer is needed. The adjustment of the leakage inductance value is affected by various factors such as the distance between windings and the external magnetic material structure. Transformers with traditional structures are very difficult to adjust the leakage inductance value through an externally added magnetic core, because this will not only change the overall structure of the transformer but may also affect its performance and reliability.
[0003] In addition, existing patents have tried to design an integrated leakage inductance by adding an additional magnetic core on the outermost side based on the design of the transformer. However, this design method has obvious drawbacks. Firstly, it increases the space volume occupied by the high-frequency transformer and is difficult to apply in some application scenarios with strict space requirements. Secondly, the addition of the leakage inductance magnetic core increases the overall loss of the high-frequency transformer, reduces its efficiency, and at the same time, the leakage inductance magnetic core affects the current distribution in the windings, further increasing the difficulty of estimating the winding loss and bringing new challenges to the design and optimization of the transformer. Summary of the Utility Model
[0004] In view of this, the utility model proposes an annular multi-winding balanced leakage inductance high-frequency transformer, aiming to effectively adjust the leakage inductance value between the windings of each transformer through a built-in leakage inductance regulator.
[0005] To achieve the above object, the utility model adopts the following technical solutions:
[0006] An annular multi-winding balanced leakage inductance high-frequency transformer includes an insulating magnetic core, transformer windings, and a leakage inductance value regulator. The insulating magnetic core has an annular structure. There are multiple transformer windings, which are wound around the annular surface of the insulating magnetic core at intervals. The leakage inductance value regulator includes an insulating base and insulating magnetic flux leakage sheets. The insulating base is fixedly arranged at the center of the insulating magnetic core. The insulating magnetic flux leakage sheets correspond to the transformer windings one by one and are distributed in an annular radiation pattern. The ends of the insulating magnetic flux leakage sheets that are close to each other are spaced apart from each other and are all arranged in the insulating base. The ends of the insulating magnetic flux leakage sheets that are far from each other are respectively connected to the inner annular surface of the insulating magnetic core and are located between two transformer windings. The size specifications of the insulating magnetic flux leakage sheets are the same or different.
[0007] To better implement the above technical solution, optionally, it is characterized in that the insulating magnetic core includes two symmetrically arranged magnetic core half-rings and insulating gaskets fixedly clamped between the two end faces of the two magnetic core half-rings. The two magnetic core half-rings and the two insulating gaskets together form an annular structure, and both are wrapped with an annular insulating shell.
[0008] Optionally, the two magnetic core half-rings and the two insulating gaskets are all connected by an adhesive method.
[0009] Optionally, the annular insulating shell includes an upper insulating half-shell and a lower insulating half-shell that is snap-connected to the upper insulating half-shell.
[0010] Optionally, the insulating magnetic flux leakage sheet includes a magnetic flux leakage sheet and a high-temperature resistant insulating tape located between the two ends of the magnetic flux leakage sheet and wrapping the magnetic flux leakage sheet.
[0011] Optionally, the material of the magnetic flux leakage sheet is a metal magnetic powder core, or a ferrite magnetic core, or a silicon steel sheet, or an amorphous nanocrystalline material.
[0012] Optionally, the outer peripheral surface of the insulating base is provided with open slots at intervals for inserting and fixing each insulating magnetic flux leakage sheet.
[0013] Optionally, it further includes a bottom plate. Each end of each group of transformer windings is provided with a pin extending downward. The bottom plate is provided with pin holes for each pin to pass through.
[0014] Optionally, it further includes a tin-penetrating plate. The tin-penetrating plate is adhesively bonded to the bottom surface of the bottom plate. Each pin hole is located outside or inside the tin-penetrating plate.
[0015] Optionally, the transformer winding uses a single-wire multi-strand combined Litz enameled copper wire, and then is wrapped with a polyimide PI film or a high-temperature resistant tape, or a multi-strand three-layer insulated wire.
[0016] The beneficial effects of the present utility model:
[0017] An annular multi-winding balanced leakage inductance high-frequency transformer of the present utility model can control the size specifications of each magnetic leakage sheet, so that each magnetic leakage sheet has a different leakage inductance value, and then accurately adjust the leakage inductance value between each transformer winding, realizing that the leakage inductance deviation value between each transformer winding of the multi-winding transformer can be regulated and the leakage inductance value between each transformer winding is adjustable.
[0018] An annular multi-winding balanced leakage inductance high-frequency transformer of the present utility model adopts radially distributed magnetic leakage sheets, which have a high space occupancy rate, a small volume, and a high power density. The annular multi-winding balanced leakage inductance high-frequency transformer can meet the design requirements of a current of 10 to 100 A and a single power of up to 20 KW. BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Figure 1 is a three-dimensional schematic diagram of an annular multi-winding balanced leakage inductance high-frequency transformer according to an embodiment of the present utility model;
[0020] Figure 2 is Figure 1 the top view of
[0021] Figure 3 is Figure 1 the bottom view of
[0022] Figure 4 is Figure 1 the exploded view of
[0023] Figure 5 is Figure 1 a three-dimensional schematic diagram of a certain angle of the leakage inductance value regulator in
[0024] Figure 6 is Figure 1 a three-dimensional schematic diagram of another angle of the leakage inductance value regulator in
[0025] REFERENCE MARKS:
[0026] Insulating magnetic core 10, magnetic core half-ring 11, insulating gasket 12, upper insulating half-shell 131, lower insulating half-shell 132, transformer winding 20, pin 21, leakage inductance value regulator 30, magnetic leakage sheet 31, high-temperature resistant insulating tape 32, insulating base 33, opening groove 331, weight reduction through hole 332, bottom plate 40, pin hole 41, tin-penetrating plate 50. DETAILED DESCRIPTION OF THE EMBODIMENTS
[0027] The technical solutions of the present utility model will be described in detail below with reference to the drawings and specific embodiments. The same components are denoted by the same reference marks.
[0028] Please refer to Figures 1 to 6, an embodiment of the present utility model discloses an annular multi-winding balanced leakage inductance high-frequency transformer, which includes an insulating magnetic core 10, a transformer winding 20, and a leakage inductance value regulator 30.
[0029] As Figure 1 shown, the insulating magnetic core 10 has an annular structure, and the transformer winding 20 is in multiple groups and is wound around the annular surface of the insulating magnetic core 10 at intervals. Specifically, the transformer winding 20 is in five groups, and the five groups of transformer windings 20 are wound around the annular surface of the insulating magnetic core 10 at equal intervals. There is a gap between each adjacent transformer winding 20. The insulating magnetic core 10 adopts an annular structure, and each transformer winding 20 has the same number of turns, which can effectively control the consistency of the DC resistance values of each transformer winding 20, ensure that the current distribution of each transformer winding 20 is more uniform during the operation of the transformer, and reduce local overheating and energy loss caused by resistance differences.
[0030] As Figure 1 , Figure 4 and Figure 5 shown, the leakage inductance value regulator 30 includes an insulating base 33 and insulating magnetic flux leakage sheets. The insulating base 33 is fixedly arranged at the center of the insulating magnetic core 10. The insulating magnetic flux leakage sheets correspond to the transformer windings 20 one by one and are distributed in an annular radiation manner. The end portions of the insulating magnetic flux leakage sheets close to each other are spaced apart from each other and are all arranged in the insulating base 33. The end portions of the insulating magnetic flux leakage sheets far from each other are respectively connected to the inner annular surface of the insulating magnetic core 10 and are located between two transformer windings 20. The size specifications of the insulating magnetic flux leakage sheets are the same or different.
[0031] In the annular multi-winding balanced leakage inductance high-frequency transformer of the present utility model, a leakage inductance value regulator 30 is arranged at the inner center of the insulating magnetic core 10. The insulating magnetic flux leakage sheet has a low magnetic permeability and will change the original magnetic circuit distribution of the insulating magnetic core 10. A part of the magnetic flux will be guided by the magnetic flux leakage sheet 31 and will not pass through all the transformer windings 20, thereby increasing the leakage magnetic flux. Since the leakage inductance is proportional to the leakage magnetic flux, the change of the leakage magnetic flux will directly affect the leakage inductance value. At the same time, by setting the magnetic flux leakage sheet 31, a high magnetic resistance area is added to the magnetic circuit. The increase of the magnetic resistance will lead to the reduction of the magnetic flux, especially the change of the leakage magnetic flux is more obvious. The change of the leakage magnetic flux will cause the corresponding change of the leakage inductance value. Therefore, by arranging the leakage inductance value regulator 30 at the inner side of the insulating magnetic core 10 and selecting insulating magnetic flux leakage sheets with different size specifications, the leakage inductance value between each transformer winding 20 can be adjusted, and further, the deviation value of the leakage inductance amount between each transformer winding 20 of the multi-winding transformer can be regulated and the leakage inductance amount value between each winding of the multi-winding transformer can be adjusted.
[0032] In an embodiment of the present utility model, the transformer winding 20 adopts a Litz enameled copper wire composed of multiple strands of a single wire, and is further wrapped with a polyimide PI film or a high-temperature resistant tape, or a multi-strand triple-insulated wire. Specifically, each group of transformer windings 20 is wound with a 0.1*450 film-coated wire for one layer, two layers or multiple layers. The number of turns of each group of transformer windings 20 is determined according to the design requirements (9 turns in the attached drawings). A leakage magnetic sheet 31 placement space is formed between adjacent transformer windings 20. Compared with copper foil, the Litz enameled copper wire has a simple preparation process, free selection of the number of strands, low high-frequency loss, can effectively reduce the temperature rise during the operation of the high-frequency transformer, reduce the weight of the transformer, and improve the heat dissipation performance and portability of the transformer.
[0033] In an embodiment of the present utility model, the insulating magnetic core 10 includes two symmetrically arranged magnetic core half-rings 11 and an insulating gasket 12 fixedly clamped between the two end faces of the two magnetic core half-rings 11. The two magnetic core half-rings 11 and the two insulating gaskets 12 together form an annular structure, and both are wrapped with an annular insulating shell. Specifically, the magnetic ring is cut along the diameter of the magnetic ring at a certain thickness. The magnetic ring preferably uses a ring-shaped manganese-zinc ferrite, and two magnetic core half-rings 11 can be formed. The cut thickness can be determined according to the requirement of the inductance. For example, if the thickness of the insulating gasket 12 is designed to be 0.1 - 0.8 mm or thicker, the cut thickness of the magnetic ring is greater than the thickness of the insulating gasket 12. The two magnetic core half-rings 11 and the two insulating gaskets 12 are all connected by an adhesive method. The sum of the thickness of the adhesive and the thickness of the insulating gasket 12 is consistent with the cut thickness, so that the two magnetic core half-rings 11 and the two insulating gaskets 12 form a circular ring structure. Three layers of high-temperature resistant tape are wound at the connection of the two magnetic core half-rings 11 and the two insulating gaskets 12, which can reinforce the connection of the two magnetic core half-rings 11 and the two insulating gaskets 12, and improve the structural stability and reliability of the insulating magnetic core 10. Then, an annular insulating shell is sleeved on the annular structure formed by the two magnetic core half-rings 11 and the two insulating gaskets 12. Specifically, the annular insulating shell includes an upper insulating half-shell 131 and a lower insulating half-shell 132 buckled with the upper insulating half-shell 131. The buckling method can be common methods in the prior art such as buckling up and down, elastic covering, etc., so that the magnetic core half-ring 11 is insulated from the transformer winding 20, and the electrical insulation performance of the transformer is enhanced.
[0034] In an embodiment of the present utility model, the insulating leakage magnetic sheet includes a leakage magnetic sheet 31 and a high-temperature resistant insulating tape 32 located between the two ends of the leakage magnetic sheet 31 and wrapping the leakage magnetic sheet 31. The material of the leakage magnetic sheet 31 is a metal magnetic powder core, or a ferrite magnetic core, or a silicon steel sheet, or an amorphous nanocrystalline material. The metal magnetic powder core such as an iron-silicon-aluminum powder core, an iron-silicon powder core, an iron-nickel powder core, and the ferrite magnetic core 10 such as a manganese-zinc power material, a manganese-zinc high magnetic permeability material, a nickel-zinc ferrite material. The leakage magnetic sheets 31 of different materials have different magnetic properties and electrical characteristics, and can be selected according to specific application requirements, broadening the applicable range of the transformer.
[0035] In an embodiment of the present utility model, the size specifications of the magnetic leakage sheet 31 are different, including one or more of the length, width, and thickness of the magnetic leakage sheet 31 being different. By adjusting the length, width, and thickness of the magnetic leakage sheet 31, the magnetic leakage inductance value of a single magnetic leakage sheet 31 can be controlled, and further, the magnetic leakage inductance value between the transformer windings 20 can be accurately adjusted, improving the adjustment accuracy and flexibility of the performance of the transformer.
[0036] As Figure 5 and Figure 6 shown, the outer peripheral surface of the insulating base 33 is provided with opening grooves 331 at intervals for inserting and fixing each insulating magnetic leakage sheet. Specifically, the insulating base 33 has a cylindrical structure, and a weight-reducing through-hole 332 is axially provided in the center of the insulating base 33. The weight-reducing through-hole 332 is a T-shaped hole with a larger bottom and a smaller top. The weight-reducing through-hole 332 can be filled with fixing glue. Five opening grooves 331 with open tops and sides are provided at intervals in the circumferential direction of the top surface of the insulating base 33 and equidistantly along the axial direction of the insulating base 33. Each insulating gasket 12 is inserted into the corresponding opening groove 331, so that five insulating magnetic leakage sheets are all inserted and fixed on the insulating base 33. The setting of the insulating base 33 can effectively control the relative positions of the five insulating magnetic leakage sheets, thereby improving the accuracy and stability of the magnetic leakage inductance value adjustment.
[0037] In an embodiment of the present utility model, it further includes a bottom plate 40 and a tin-penetrating plate 50. The two ends of each group of transformer windings 20 are respectively provided with pins 21 extending downward. The bottom plate 40 is made of an epoxy bottom plate or an injection-molded bottom plate. The bottom plate 40 is provided with pin holes 41 for each pin 21 to pass through. The setting of the pin holes 41 can accurately position the sizes of the pins 21 to facilitate the direct assembly of the transformer onto the PCB board. The tin-penetrating plate 50 is adhesively attached to the bottom surface of the bottom plate 40. Each pin hole 41 is located outside or inside the tin-penetrating plate 50, so that the pins 21 and the tin-penetrating plate 50 do not contact each other, ensuring the reliability and safety of the electrical connection.
[0038] The assembly method of a ring-shaped multi-winding balanced magnetic leakage high-frequency transformer of the present utility model is as follows:
[0039] S10. Cut the magnetic ring along a diameter of the magnetic ring and by a certain thickness. The thickness cut off from the magnetic ring is greater than the thickness of the insulating gasket 12. Then, adhesively attach the insulating gasket 12 at the cut surface of the magnetic core half-ring 11, so that the two magnetic core half-rings 11 and the two insulating gaskets 12 form a ring-shaped structure. Then, wind three layers of tape around the connection between the magnetic core half-ring 11 and the insulating gasket 12 for reinforcement, and then sleeved a ring-shaped insulating shell on the ring-shaped structure jointly formed by the two magnetic core half-rings 11 and the two insulating gaskets 12.
[0040] S20. Uniformly wind five groups of transformer windings 20 in the circumferential direction of the insulating magnetic core 10, and solder the ends of the transformer windings 20 to connect the pins 21;
[0041] S30. Fix and insert the magnetic flux leakage sheet 31 onto the insulating base 33;
[0042] S40. Glue the tin-penetrating plate 50 to the bottom surface of the bottom plate 40, fix the insulating base 33 to the top surface of the bottom plate 40 by gluing, and adhesively connect the magnetic flux leakage sheet 31 to the insulating core 10.
[0043] S50. Fix all components by dispensing glue and conduct tests.
[0044] For a multi-winding balanced leakage inductance high-frequency transformer of the present utility model, by controlling the dimensional specifications of each magnetic flux leakage sheet 31, each magnetic flux leakage sheet 31 has a different leakage inductance value, so that the leakage inductance value between each transformer winding 20 can be accurately adjusted, and the leakage inductance deviation value between each transformer winding 20 of the multi-winding transformer can be regulated and the leakage inductance value between each winding of the multi-winding transformer can be adjusted. By using the radially distributed magnetic flux leakage sheets 31, it has high space utilization rate, small volume and high power density. The multi-winding balanced leakage inductance high-frequency transformer can meet the design requirements of a current of 10 to 100 A and a single power of up to 20 KW, and is applicable to various high-power and high-precision power electronics application scenarios.
[0045] The above has introduced the technical solution of the present utility model in detail in combination with specific embodiments, and the described specific embodiments are used to help understand the idea of the present utility model. The derivations and deformations made by those skilled in the art based on the specific embodiments of the present utility model also fall within the protection scope of the present utility model.
Claims
1. A toroidal multi-winding balanced leakage inductance high-frequency transformer, characterized in that: It comprises an insulating magnetic core (10), a transformer winding (20) and a leakage inductance value regulator (30); The insulating magnetic core (10) has a ring-shaped structure; The transformer windings (20) are multiple and are wound at intervals on the annular surface of the insulating magnetic core (10); The leakage inductance value adjuster (30) comprises an insulating base (33) and an insulating leakage magnetic sheet. The insulating base (33) is fixedly arranged at the center of the insulating magnetic core (10). The insulating leakage magnetic sheets correspond to the transformer windings (20) one by one and are radially distributed in a ring shape. The ends of the insulating leakage magnetic sheets close to each other are spaced apart from each other and are all arranged in the insulating base (33). The ends of the insulating leakage magnetic sheets far away from each other are respectively connected to the inner annular surface of the insulating magnetic core (10) and are located between the two transformer windings (20). The size specifications of the insulating leakage magnetic sheets are the same or different.
2. The toroidal multi-winding balanced leakage inductance high-frequency transformer according to claim 1, characterized in that: The insulating magnetic core (10) comprises two symmetrically arranged magnetic core half rings (11) and an insulating gasket (12) fixedly clamped between the two end surfaces of the two magnetic core half rings (11); the two magnetic core half rings (11) and the two insulating gaskets (12) together form an annular structure and are both wrapped with an annular insulating shell.
3. The toroidal multi-winding balanced leakage inductance high-frequency transformer according to claim 2, characterized in that: The two magnetic core half rings (11) and the two insulating gaskets (12) are connected by gluing.
4. The toroidal multi-winding balanced leakage inductance high frequency transformer according to claim 3, characterized in that: The annular insulating shell comprises an upper insulating half shell (131) and a lower insulating half shell (132) buckled with the upper insulating half shell (131).
5. The toroidal multi-winding balanced leakage inductance high-frequency transformer according to claim 4, characterized in that: The insulating magnetic leakage sheet comprises a magnetic leakage sheet (31) and a high temperature resistant insulating adhesive tape (32) located between two ends of the magnetic leakage sheet (31) and wrapping the magnetic leakage sheet (31).
6. The toroidal multi-winding balanced leakage inductance high frequency transformer according to claim 5, characterized in that: The material of the magnetic leakage sheet (31) is a metal magnetic powder core, a ferrite magnetic core, a silicon steel sheet, or an amorphous nanocrystalline material.
7. The toroidal multi-winding balanced leakage inductance high frequency transformer according to claim 6, characterized in that: The outer peripheral surface of the insulating base (33) is provided with open grooves (331) at intervals for inserting and fixing the insulating magnetic leakage sheets.
8. The toroidal multi-winding balanced leakage inductance high frequency transformer according to claim 7, characterized in that: It also comprises a bottom plate (40), and pins (21) extending downwards are respectively provided at both ends of each group of transformer windings (20), and the bottom plate (40) is provided with pin holes (41) for each pin (21) to pass through.
9. The toroidal multi-winding balanced leakage inductance high frequency transformer according to claim 8, characterized in that: It also comprises a tin-penetrating plate (50), wherein the tin-penetrating plate (50) is glued to the bottom surface of the bottom plate (40), and each pin hole (41) is located on the outside or inside of the tin-penetrating plate (50).
10. The toroidal multi-winding balanced leakage inductance high frequency transformer according to claim 9, characterized in that: Each transformer winding (20) is made of a single-wire, multi-strand Litz enameled copper wire, which is then coated with a polyimide PI film or a high-temperature resistant tape, or a multi-strand three-layer insulated wire.