High-frequency transformer for charging new energy vehicle

Abstract

The utility model relates to a high-frequency transformer for charging a new energy vehicle. The high-frequency transformer comprises a winding coil, a framework, a magnetic core assembly and a PCB (Printed Circuit Board), the magnetic core assembly comprises three pairs of independent magnetic cores with the same shape and structure, and the magnetic core assembly and the winding coil are isolated in an overhead mode through the framework to be in a non-contact state. 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 the technology of electronic transformers, and particularly relates to a high-frequency transformer for charging new energy vehicles. Background Art

[0002] High-frequency transformers are commonly used in existing new energy vehicle charging piles, and their structures are composed of coils, skeletons, and ferrite cores; in actual operation, in addition to the heat rise caused by the resistance of the coils themselves, the ferrite cores also generate heat. Alternating magnetic fields generate induced currents in the ferrite cores, which causes the ferrite cores to heat up, thereby transferring heat to the coils and increasing the coil temperature. If heat dissipation is not timely, the coils may be damaged. Content of the Utility Model

[0003] Aiming at the technical problems existing in the prior art, the utility model provides a high-frequency transformer for charging new energy vehicles, which has the effects of low loss, good heat dissipation effect, high current-carrying capacity, uniform current distribution, safety and reliability.

[0004] To solve the above problems, the utility model adopts the following technical solutions:

[0005] A high-frequency transformer for charging new energy vehicles includes a winding coil, a skeleton, a magnetic core assembly, and a PCB board; the winding coil is divided into a high-voltage winding and a low-voltage winding, both of which are wound with film-coated wires with self-adhesive layers wrapped around multi-strand enameled wires; the high-voltage winding and the low-voltage winding are formed into a hollow coil with a long middle part and arc-shaped ends at both ends by overlapping winding; the respective lead ends of the high-voltage winding and the low-voltage winding are led out and welded to different pins on the PCB board; the magnetic core assembly includes three pairs of independent magnetic cores with the same shape and structure, and each pair of independent magnetic cores is formed by inserting and gluing two E-shaped magnetic core blocks together, and an air gap with a fixed distance is formed at the inserted and glued part; the skeleton is composed of a wire-wrapping cylinder and end plates of the cylinder, the wire-wrapping cylinder is wound with a porous mesh insulating board, and the end plates of the cylinder are two front and rear plates, both of which are square-shaped alumina single plates, and the surface of each end plate of the cylinder is sequentially provided with a left boss, a first partition boss, a second partition boss, and a right boss from left to right at equal distances; the left boss and the right boss are the left and right frame edges of the cylinder end plate, the first partition boss is composed of two identical symmetrical halves and is respectively distributed on the two long frame edges of the cylinder end plate, and the second partition boss is also composed of two identical symmetrical halves and is respectively distributed on the two long frame edges of the cylinder end plate; three limiting grooves are formed between the left boss and the first partition boss, between the first partition boss and the second partition boss, and between the second partition boss and the right boss on each end plate of the cylinder; the E-shaped magnetic core blocks of the three pairs of independent magnetic cores of the magnetic core assembly are inserted and combined with the skeleton, so that the central columns of the three pairs of independent magnetic cores pass through the wire-wrapping cylinder of the skeleton together, and the magnetic core roots of the three pairs of independent magnetic cores are respectively pressed in the above three limiting grooves; gaps are generated between the independent magnetic cores and between the independent magnetic cores and the winding coil.

[0006] Compared with the prior art, the magnetic core assembly and the winding coil of the present utility model are separated and isolated by a special skeleton and are in a non-contact state; the gaps of line contact between the skeleton and the winding coil, the gaps between the independent magnetic cores and between the independent magnetic cores and the winding coil form an air flow heat dissipation channel. The thermal performance of the transformer is greatly improved, the magnetic loss can be effectively reduced, and it is more beneficial to the heat dissipation of the film-coated wire under the condition of large charging current for new energy vehicles. Description of the Drawings

[0007] The present utility model will be further described in detail below in conjunction with the drawings and specific embodiments.

[0008] Figure 1 It is the front view schematic diagram of the present utility model.

[0009] Figure 2 is Figure 1 the left view schematic diagram of

[0010] Figure 3 is Figure 1 the A-A sectional view schematic diagram of

[0011] Figure 4 This is a schematic diagram of the winding coil of the present utility model.

[0012] Figure 5 This is a front view schematic diagram of the skeleton of the present utility model.

[0013] Figure 6 is Figure 5 side view schematic diagram of.

[0014] The reference numerals are: 1 winding coil; 2 skeleton; 3 magnetic core assembly; 4 PCB board; 5 pins; 6 air gap; 7 wire bobbin; 8 bobbin end plate; 9 left boss; 10 first partition boss; 11 second partition boss; 12 right boss; 13 limit groove. Specific embodiments

[0015] The present utility model will be further described below in conjunction with the drawings and embodiments.

[0016] See Figures 1-4 , A high-power transformer for a new energy vehicle charging pile, comprising a winding coil 1, a magnetic core assembly 2 and a PCB board 3; the magnetic A high-frequency transformer for new energy vehicle charging, comprising a winding coil 1, a skeleton 2, a magnetic core assembly 3 and a PCB board 4; the winding coil 1 is divided into a high-voltage winding and a low-voltage winding, both of which are wound with film wires having self-adhesive layers wrapped around multi-strand enameled wires; the high-voltage winding and the low-voltage winding are stacked and wound into a hollow coil with a long middle and arc-shaped ends at both ends; the respective lead ends of the high-voltage winding and the low-voltage winding are respectively led out and welded to different pins 5 of the PCB board 4; the magnetic core assembly 3 includes three pairs of independent magnetic cores with the same shape and structure, and each pair of independent magnetic cores is formed by inserting and gluing two E-shaped magnetic core blocks opposite to each other, and an air gap 6 with a fixed distance is formed at the insertion and gluing position.

[0017] See Figures 5-6, the described framework 2 is composed of a wire coil cylinder 7 and cylinder end plates 8. The wire coil cylinder 7 is rolled from a porous mesh insulating board. The cylinder end plates 8 are two pieces, front and back, both being square-shaped alumina single plates. On the surface of each cylinder end plate 8, there are successively arranged a left boss 9, a first partition boss 10, a second partition boss 11, and a right boss 12 at equal intervals from left to right; among them, the left boss 9 and the right boss 12 are the left and right frame edges of the cylinder end plate 8, the first partition boss 10 is composed of two identical symmetric halves and is respectively distributed on the two long frame edges of the cylinder end plate 8, and the second partition boss 11 is also composed of two identical symmetric halves and is respectively distributed on the two long frame edges of the cylinder end plate 8; three limiting grooves 13 are formed between the left boss 9 and the first partition boss 10, between the first partition boss 10 and the second partition boss 11, and between the second partition boss 11 and the right boss 12 on each cylinder end plate 8; the E-shaped core blocks of the three pairs of independent cores of the core assembly 3 are inserted and combined with the described framework 2, so that the central columns of the three pairs of independent cores pass through the wire coil cylinder 7 of the above-mentioned framework 2 together, and the core roots of the three pairs of independent cores are respectively pressed in the above-mentioned three limiting grooves 13; there are spacing gaps between independent cores and between independent cores and the winding coil 1.

[0018] Furthermore, the alumina single plate is a plate made of alumina as the main raw material by a high-temperature sintering process; the alumina single plate is a ceramic material with high hardness, high wear resistance, and high corrosion resistance, and has excellent mechanical properties and chemical stability.

[0019] In this embodiment, three pairs of independent cores with the same shape and structure are used together with the framework 2 to be overhead and isolated into a non-contact state; it ensures the heat dissipation and ventilation of the winding coil 1; the heat generated by the energy storage of the central columns of the three pairs of independent cores of the transformer is dissipated by air convection. At the same time, the magnetic field line distribution and magnetic flux will not be generated on a single integral core. The three pairs of independent cores are separated from each other, so that the magnetic field line distribution is evenly dispersed; the effective cross-sectional area of the core assembly 2 of the transformer under the same specifications is increased, and the saturation magnetic flux density BS value is increased, thereby reducing the current loss and improving the electromagnetic performance and electromagnetic conversion efficiency of the transformer.

[0020] Although the embodiments of the present invention have been shown and described above, for those of ordinary skill in the art, it can be understood that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principle and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A high-frequency transformer for charging a new energy vehicle, comprising a winding coil (1), a frame (2), a magnetic core assembly (3) and a PCB board (4); characterized in that: The winding coil (1) 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 formed into a hollow coil with a long middle and arc-shaped ends by overlapping winding; the lead ends of the high-voltage winding and the low-voltage winding are respectively led out and welded to different pins (5) of a PCB board (4); the magnetic core assembly (3) comprises three pairs of independent magnetic cores of the same shape and structure, and each pair of independent magnetic cores adopts two E-shaped magnetic core blocks inserted into each other. The frame (2) is composed of a wire wrapping barrel (7) and a wrapping barrel end plate (8), the wire wrapping barrel (7) is made of a porous mesh insulating plate, and the wrapping barrel end plate (8) is composed of two front and rear pieces, both of which are square-shaped aluminum oxide single plates. The surface of each wrapping barrel end plate (8) is provided with a left boss (9), a first separation boss (10), a second separation boss (11) and a right boss (12) in order from left to right at equal distances; the left boss The left and right bosses (9) and (12) are the left and right frame edges of the barrel end plate (8); the first separating boss (10) is composed of two identical and symmetrical halves respectively distributed on the two long frame edges of the barrel end plate (8); the second separating boss (11) is also composed of two identical and symmetrical halves respectively distributed on the two long frame edges of the barrel end plate (8); so that the left boss (9) and the first separating boss (10), the first separating boss (10) and the second separating boss (11) on each barrel end plate (8) are spaced apart from each other. Three limiting grooves (13) are formed between the first and second separating bosses (11) and the right boss (12); the E-shaped magnetic core blocks of the three pairs of independent magnetic cores of the magnetic core assembly (3) are inserted and assembled with the skeleton (2), so that the central columns of the three pairs of independent magnetic cores pass through the wire wrapping tube (7) of the skeleton (2) together, and the magnetic core roots of the three pairs of independent magnetic cores are pressed into the three limiting grooves (13) respectively; so that there are spacing gaps between the independent magnetic cores and between the independent magnetic cores and the winding coil (1).

2. The high-frequency transformer for charging new energy vehicles according to claim 1 is characterized in that: The alumina veneer is a plate made of alumina as the main raw material through a high-temperature sintering process.

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