Nanocrystalline voltage conversion and filtering integrated device for OBC

Abstract

The utility model relates to a nanocrystalline voltage conversion and filtering integrated device for an OBC, and belongs to the technical field of OBC transformers, the nanocrystalline voltage conversion and filtering integrated device comprises a base, a framework, a magnetic core assembly and a winding, the framework, the magnetic core assembly and the winding are installed on the base, the framework comprises an Lr framework and a transformer framework, and the magnetic core assembly comprises multiple sections of magnetic core blocks. And air gap sheets are adhered among the multiple sections of magnetic core blocks of the magnetic core assembly. According to the nanocrystalline voltage conversion and filtering integrated device for the OBC, a magnetic core block is formed by a nanocrystalline strip in a winding mode through the magnetic core assembly, so that the saturation flux density of a product is improved, the section of a magnetic core is small, the power density of the product is increased, the size of the product is reduced, the magnetic core assembly is formed by connecting the magnetic core block through an air gap piece, and the thickness of the air gap piece can be adjusted; the needed Lr inductance is changed, the heat exchange efficiency of the magnetic core and the copper wire is improved through the hollow structure of the product framework, the power density is improved to 65 KW / L from 40 KW / L through the combined structure mode of the product Lm and Lr, and good generalization performance is achieved.

Description

Technical Field

[0001] This application relates to the technical field of OBC transformers, and specifically to a nanocrystalline voltage conversion and filtering integrated device for OBC. Background Technique

[0002] The OBC transformer is a transformer in the on-vehicle charger. The product is mainly used in the OBC of new energy vehicles to achieve the functions of voltage conversion and power purification. Through the characteristics of high magnetic flux density and low loss of nanocrystals, the power density of the product is effectively increased from 40KW / L to 65KW / L, further promoting the development direction of high power density of OBC.

[0003] At present, the iron cores of existing transformer products are all made of manganese zinc, with low saturation magnetic density. At the same time, Lr and Lm are made separately, occupying a large space in the OBC. In view of the above problems, a nanocrystalline voltage conversion and filtering integrated device for OBC is proposed to solve the above problems. Utility Model Content

[0004] In view of the deficiencies of the prior art, this application provides a nanocrystalline voltage conversion and filtering integrated device for OBC, which has the advantages of adopting a mouth-shaped magnetic core structure to make Lr and Lm into an integrated structure, reducing winding copper loss and increasing the inductance of Lr (mH level), achieving a better filtering effect, and saving mineral resources.

[0005] To achieve the above object, this application provides the following technical solution: A nanocrystalline voltage conversion and filtering integrated device for OBC, including a base, a skeleton mounted on the base, a magnetic core assembly and windings. The skeleton includes an Lr skeleton and a transformer skeleton;

[0006] The magnetic core assembly includes multiple magnetic core blocks, and air gap sheets are bonded between the multiple magnetic core blocks of the magnetic core assembly;

[0007] The windings include a primary winding and a secondary winding. The primary winding is wound around both the Lr skeleton and the transformer skeleton at the same time and is integrally formed in a series connection manner; the secondary winding is only wound around the transformer skeleton.

[0008] Further, the magnetic core block is a nanocrystalline tape wound into a cylindrical structure, and an insulating paint is coated on the non-contact surface of the magnetic core block.

[0009] Further, the air gap sheet is a hollowed-out part, and an adhesive is coated on the hollowed-out part to bond the magnetic core blocks.

[0010] Further, both the primary winding and the secondary winding extend with pins passing through the base, and four endpoints are distributed at the lower end of the base for the pins.

[0011] Further, insertion lugs are integrally extended at the lower ends of the Lr skeleton and the transformer skeleton, and buckle grooves for snap connection of the insertion lugs are formed on the base.

[0012] Further, support feet are fixedly installed at the bottom of the base.

[0013] Compared with the prior art, the technical solution of the present application has the following beneficial effects:

[0014] For this OBC nano-crystalline voltage conversion and filtering integrated device, by arranging the magnetic core assembly to be composed of nano-crystalline strips wound into magnetic core blocks, the saturation magnetic density of the product is increased, the cross-section of the magnetic core is small, the power density of the product is increased, and the volume is reduced. The magnetic core blocks are connected by air gap sheets to form the magnetic core assembly. The required Lr inductance can be changed by adjusting the thickness of the air gap sheets. The hollow structure of the product skeleton improves the heat exchange efficiency between the magnetic core and the copper wire. The combined structure of Lm and Lr of the product increases the power density from 40KW / L to 65KW / L, and has good popularization. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 is the bottom view of the overall structure of the present application;

[0016] Figure 2 is the three-dimensional view of the overall structure of the present application;

[0017] Figure 3 is the exploded schematic view of the magnetic core assembly of the present application.

[0018] In the figure: 1, base; 2, Lr skeleton; 3, transformer skeleton; 4, magnetic core assembly; 5, primary winding; 6, secondary winding; 7, pin; 8, air gap sheet; 9, buckle groove; 10, insertion lug; 11, support foot. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0019] Next, the technical solutions in the embodiments of the present application will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present application without creative efforts shall fall within the protection scope of the present application.

[0020] Please refer to Figures 1 to 3 , a nano-crystalline voltage conversion and filtering integrated device for OBC in this embodiment, includes a base 1, a skeleton installed on the base 1, a magnetic core assembly 4 and windings.

[0021] Specifically, the skeleton includes an Lr skeleton 2 and a transformer skeleton 3. The magnetic core assembly 4 adopts an integrated structure and is installed through the Lr skeleton 2 and the transformer skeleton 3. At the same time, it is used to divide the windings into two groups and arrange them on the base 1.

[0022] In this embodiment, the magnetic core assembly 4 includes multiple magnetic core blocks, and air gap sheets 8 are bonded between the multiple magnetic core blocks of the magnetic core assembly 4.

[0023] Specifically, the magnetic core block is formed into a cylindrical structure by winding a nanocrystalline strip, and the outer surface of the magnetic core block is coated with insulating paint on the non-contact surface, so that the magnetic core surface can withstand a withstand voltage of at least 100V AC or more.

[0024] Furthermore, the air gap sheet 8 is made by a hollowing method, and an adhesive is coated at the hollowed-out part for bonding and connecting multiple magnetic core blocks into the magnetic core assembly 4.

[0025] It should be noted that the windings include a primary winding 5 and a secondary winding 6. The primary winding 5 is wound around both the Lr skeleton 2 and the transformer skeleton 3 and is formed in a series connection as a whole; the secondary winding 6 is only wound around the transformer skeleton 3.

[0026] Preferably, the winding copper wire is formed by multiple strands of enameled copper wire, so that the copper wire can withstand a switching frequency of more than 100KHz.

[0027] The skeleton also adopts a hollowing method, which enables faster heat exchange between the copper wire and the magnetic core while ensuring that the copper wire and the magnetic core can withstand a high voltage of 5kV AC, thereby increasing the product usage power.

[0028] In this embodiment, both the primary winding 5 and the secondary winding 6 extend pins 7 that penetrate the base 1, and the pins 7 are distributed with four endpoints at the lower end of the base 1.

[0029] In specific implementation, the four endpoints are divided into an end 1, an end 2, an end 3, and an end 4. The end 1 and the end 2 are integrally extended by the primary winding 5 wound outside the Lr skeleton 2, and the end 3 and the end 4 are integrally extended by the secondary winding 6 wound outside the transformer skeleton 3.

[0030] The voltage conversion of the above transformer component is carried out according to the different turns ratios of the 1-2 ends and the 3-4 ends to perform voltage ratio conversion to achieve the voltage conversion function; the 1-2 ends are connected to electricity, the 3-4 ends are short-circuited, and the leakage inductance of the 1-2 ends at the feedback point is obtained to achieve the Lr resonant inductance of the circuit. The circuit is filtered through this Lr, so as to realize the functions of voltage conversion and filtering in one.

[0031] In this embodiment, insertion lugs 10 are integrally extended at the lower ends of the Lr core 2 and the transformer core 3. A buckle groove 9 for snap connection of the insertion lugs 10 is formed on the base 1. Through the design of the insertion lugs 10, the installation space of the Lr core 2 and the transformer core 3 can be saved, and the installation is convenient at the same time.

[0032] It should be noted that a support foot 11 is fixedly installed at the bottom of the base 1 for quickly inserting into the PCB board for welding, which is convenient for installing the product in a horizontal manner, effectively solving the height space of the OBC, making the upper and lower copper wire heat dissipation surfaces of the product closer to the OBC water cooling plate, and improving the power density.

[0033] The working principle of the above embodiment is as follows:

[0034] The magnetic core assembly 4 is formed by winding a nanocrystalline strip to form a plurality of magnetic core blocks. The magnetic core is coated with insulating paint on the non-contact surface by covering with insulating paint, and an air gap sheet 8 is placed on the contact surface of the magnetic core. Thus, by changing the thickness of the air gap sheet 8, the required Lr inductance can be adjusted. The product is installed horizontally, effectively solving the height space of the OBC. The magnetic core assembly 4 is fixed to the base 1 through the Lr core 2 and the transformer core 3. Specifically, the insertion lugs 10 integrated with the Lr core 2 and the transformer core 3 are snap-fixed to the base 1, and then the primary winding 5 and the secondary winding 6 of the winding are wound outside the core to complete the installation of the compact structure of the product.

[0035] It should be noted that in this article, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the term "comprising", "including" or any other variation thereof is intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements not only includes those elements, but also includes other elements not expressly listed, or also includes elements inherent to such process, method, article or device. Without further limitation, an element defined by the statement "including a..." does not exclude the existence of additional identical elements in the process, method, article or device including the element.

[0036] Although the embodiments of the present application have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principle and spirit of the present application. The scope of the present application is defined by the appended claims and their equivalents.

Claims

1. A nanocrystalline voltage conversion and filtering integrated device for OBC, comprising a base (1), a skeleton mounted on the base (1), a magnetic core assembly (4) and windings, characterized in that: The skeleton includes an Lr skeleton (2) and a transformer skeleton (3); The magnetic core assembly (4) includes multiple magnetic core blocks, and an air gap sheet (8) is bonded between the multiple magnetic core blocks of the magnetic core assembly (4); The winding includes a primary winding (5) and a secondary winding (6). The primary winding (5) is wound around both the Lr skeleton (2) and the transformer skeleton (3) and is formed in a series connection as a whole; the secondary winding (6) is only wound around the transformer skeleton (3).

2. The nanocrystalline voltage conversion and filtering integrated device for OBC according to claim 1, characterized in that: The magnetic core blocks are nanocrystalline tapes wound into a cylindrical structure, and the non-contact surfaces of the magnetic core blocks are coated with insulating paint.

3. An integrated nanocrystalline voltage conversion and filtering device for OBC according to claim 1, characterized in that: The air gap sheet (8) is a hollowed-out part, and the hollowed-out part is coated with an adhesive to bond the magnetic core blocks.

4. An integrated nanocrystalline voltage conversion and filtering device for OBC according to claim 1, characterized in that: Both the primary winding (5) and the secondary winding (6) extend pins (7) that penetrate through the base (1), and the pins (7) have four endpoints distributed at the lower end of the base (1).

5. An integrated nanocrystalline voltage conversion and filtering device for OBC according to claim 1, characterized in that: The lower ends of the Lr skeleton (2) and the transformer skeleton (3) are integrally extended with insertion lugs (10), and the base (1) is provided with a buckle groove (9) for snap connection with the insertion lugs (10).

6. An integrated nanocrystalline voltage conversion and filtering device for OBC according to claim 1, characterized in that: The bottom of the base (1) is also fixedly installed with support feet (11).

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