LLC transformer with high power density

Abstract

The utility model provides a high power density LLC transformer, which comprises a winding framework, a split magnetic core and a winding wire, the winding framework comprises an upper framework layer and a lower framework layer, a slot gap is arranged between the upper framework layer and the lower framework layer, the inner layer of the winding framework is in a similar ellipse shape on an overlook surface, the split magnetic core is arranged in the winding framework, and the winding wire is arranged in the split magnetic core. The magnetic cores, located in the interval height of the upper framework layer, of the upper layer are separated from the magnetic cores located in the interval height of the lower framework layer; the winding wire coil is wound on the outer side of the winding framework, high-power output is provided, meanwhile, the size of the transformer is reduced, utilization of the internal space of a vehicle is optimized, an electric vehicle charging system is more compact, and flexibility is provided for designing more diversified vehicle types.

Description

TECHNICAL FIELD

[0001] The utility model relates to construction instrument equipment technical field, concretely to a high power density LLC transformer. BACKGROUND

[0002] The electric vehicle (EV) industry market urgently needs OBC products with high efficiency and high power density to support the demand for long-distance travel and fast charging. The existing vehicle-mounted charging technology is limited in efficiency and volume, and technical innovation is urgently needed to improve energy utilization efficiency and reduce space occupation. The limitations of on-board space force vehicle-mounted charging equipment to be more integrated and high-power. The existing vehicle-mounted transformer is still in the form of a cylindrical core and a coiled external winding. After setting a protection outside this type of transformer, a large amount of side four-corner space will be lost, and a high-density and high-integrated transformer cannot be formed inside the skeleton. The transformer occupies a large space and has poor utilization rate. Moreover, the efficiency of the cylindrical transformer is low, which cannot meet the requirements of the development trend of existing electric vehicles, and the applicability is poor.

[0003] To achieve the above-mentioned purpose, the utility model provides a high power density LLC transformer, which can solve the problems raised in the background technology. UTILITY MODEL CONTENTS

[0004] The utility model takes the following technical solutions to achieve:

[0005] A high power density LLC transformer, comprising a winding skeleton, a split magnetic core, and a winding wire, the winding skeleton comprises an upper skeleton layer and a lower skeleton layer, a split slot gap is provided between the upper skeleton layer and the lower skeleton layer, the inner layer of the winding skeleton is in the form of an ellipse on the top view, the split magnetic core is located inside the winding skeleton, the magnetic core located in the height interval of the upper skeleton layer is separated from the magnetic core located in the height interval of the lower skeleton layer; the winding wire is coiled on the outside of the winding skeleton.

[0006] Preferably, the winding skeleton comprises an elliptical pipe wall and a plurality of winding discs, the winding discs are fixed to the circumferential side of the elliptical pipe wall and are arranged in intervals from top to bottom, one side of the uppermost winding disc is provided with a terminal post, and the terminal post is used to fix the outlet end of the winding wire.

[0007] Preferably, the plurality of winding discs is at least three, the upper skeleton layer is located between the top winding disc and the middle winding disc, and the lower skeleton layer is located between the bottom winding disc and the middle winding disc.

[0008] A plurality of heat dissipation holes are provided on each of the plurality of winding discs.

[0009] Preferably, a plurality of vertical grooves are provided on the side walls of the upper skeleton layer and the lower skeleton layer.

[0010] Preferably, the winding wire includes an inner winding and an outer winding, the outer winding is wound around the outside of the inner winding, and the winding wire is respectively wound around the outer walls of the upper skeleton layer and the lower skeleton layer.

[0011] Preferably, an outer shell is provided on the outside of the winding skeleton, and the outer shell includes an upper and lower combined cover plates. A core pressure plate is provided on the upper part of the split magnetic core, and the upper and lower combined cover plates are used to press the core pressure plate and the split magnetic core.

[0012] Preferably, a downward pressure type guard plate is provided on the outside of the outer shell, and the downward pressure type guard plate is a split guard plate, which is tightly attached to the top and side of the outer shell.

[0013] Preferably, an outer mounting plate is provided on the peripheral side of the winding skeleton, a filling body is provided on the inner wall of the outer mounting plate, the winding skeleton and the winding wire are in contact with the filling body, and there is a net friction extrusion effect between the side wall of the outer mounting plate and the downward pressure guard plate; a mounting frame is provided on the outside of the outer mounting plate.

[0014] Compared with the prior art, the beneficial effects of the present invention are:

[0015] 1. The utility model improves the structure of the magnetic core and designs it into an EDX-like elliptical structure based on the structure of the conventional ED cube, thereby making full use of space, improving power density and reducing volume.

[0016] 2. The utility model changes the design of the middle magnetic core and the core gap to reduce the eddy current magnetic column and improve efficiency.

[0017] 3. The utility model optimizes the design of the split-disk elliptical skeleton, integrates the resonant inductor and the transformer, and adjusts the leakage inductance value through the slot design to meet the requirements of the resonant inductor and reduce the volume.

[0018] 4. The utility model increases heat dissipation holes to allow glue to penetrate into the interior, which helps to dissipate heat and improve work efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a schematic diagram of the overall structure of the utility model;

[0020] Figure 2 This is a schematic diagram of the outer shell and winding skeleton structure of the utility model;

[0021] Figure 3 This is a schematic structural diagram of the winding skeleton and winding wire of the utility model;

[0022] Figure 4This is a side structural diagram of the outer shell and winding skeleton of the utility model;

[0023] Figure 5 This is a schematic structural diagram of the split magnetic core inside the outer shell of the utility model;

[0024] Figure 6 This is a schematic diagram of the structure of the winding skeleton of the utility model;

[0025] Figure 7 This is a schematic diagram of the split magnetic core and the upper skeleton layer structure of the present utility model;

[0026] Figure 8 This is a schematic diagram of the magnetic core pressing plate and heat dissipation structure of the utility model;

[0027] Figure 9 This is a three-dimensional diagram of the winding arrangement of the winding wire of the present invention.

[0028] In the figure: 1. External mounting plate; 2. External housing; 3. Winding frame; 4. Magnetic core pressure plate; 5. Split magnetic core; 6. Terminal pile; 7. Winding wire; 8. Down-pressed guard plate; 9. Filling body;

[0029] 21. Upper and lower combined cover plates; 31. Slot gap; 32. Upper frame layer; 33. Lower frame layer; 34. Heat dissipation holes; 71. Inner winding; 72. Outer winding. DETAILED DESCRIPTION

[0030] In order to facilitate the understanding of the present invention, the present invention will be described more comprehensively below with reference to the relevant drawings. Several embodiments of the present invention are given in the drawings, but the present invention can be implemented in different forms and is not limited to the embodiments described in the text. On the contrary, these embodiments are provided to make the content disclosed in the present invention more thorough and comprehensive.

[0031] It should be noted that when an element is referred to as being "fixed on" another element, it may be directly on the other element or there may be a central element. When an element is considered to be "connected to" another element, it may be directly connected to the other element or there may be a central element at the same time. The terms "vertical", "horizontal", "left", "right" and similar expressions used in this article are for illustrative purposes only.

[0032] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly used by technicians in the technical field of the present invention. The terms used in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention. The term "and / or" used herein includes any and all combinations of one or more related listed items.

[0033] The present invention will be described in further detail below with reference to the accompanying drawings.

[0034] The specific implementation of the utility model is as follows: Figure 2-8 , including a winding skeleton 3, a split magnetic core 5, and a winding wire 7. The winding skeleton 3 includes an upper skeleton layer 32 and a lower skeleton layer 33. A slot gap 31 is provided between the upper skeleton layer 32 and the lower skeleton layer 33. The inner layer of the winding skeleton 3 is elliptical in a top view. The split magnetic core 5 is located inside the winding skeleton 3. The upper magnetic core located within the height interval of the upper skeleton layer 32 is separated from the magnetic core located within the height interval of the lower skeleton layer 33. The winding wire 7 is coiled on the outside of the winding skeleton 3. The generation of the split magnetic core 5 can obtain better efficiency by expanding the gap of the split magnetic core 5 in the horizontal direction by fixing it up and down, and can adjust the leakage inductance value to meet the requirements of the resonant inductance and reduce the volume by using the separation method of the slot gap 31.

[0035] Please refer to Figures 1-8 The winding skeleton 3 includes an elliptical through-tube wall and a plurality of winding discs, which are fixed to the circumference of the elliptical barrel tube wall and arranged at intervals from top to bottom. A terminal post 6 is provided on one side of the topmost winding disc, and the terminal post 6 is used to fix the outlet end of the winding wire 7;

[0036] The number of the multi-layer winding discs is at least three, the upper skeleton layer 32 is located between the top winding disc and the middle winding disc, and the lower skeleton layer 33 is located between the bottom winding disc and the middle winding disc;

[0037] A plurality of heat dissipation holes 34 are provided on each of the plurality of winding disks;

[0038] The side walls of the upper skeleton layer 32 and the lower skeleton layer 33 are both provided with a plurality of vertical slot holes 35. The arrangement of the heat dissipation holes 34 and the vertical slot holes 35 can better achieve the heat conduction effect at each position and facilitate the simulation and actual testing of the product to optimize the design and thermal conductivity of the material.

[0039] Please pay attention to Figure 9 The winding wire 7 includes an inner winding 71 and an outer winding 72. The outer winding 72 is wound around the outside of the inner winding 71. The winding wire 7 is respectively wound around the outer walls of the upper skeleton layer 32 and the lower skeleton layer 33. The winding structure is optimized, the leakage inductance is easy to adjust, and the versatility is good. The wire specification is 0.04mm*3000P, which reduces AC loss.

[0040] Please pay attention to Figure 1-3 、 Figure 7-9The outer shell 2 is provided on the outside of the winding skeleton 3, and the outer shell 2 includes an upper and lower combined cover plates 21. The upper part of the split magnetic core 5 is provided with a magnetic core pressing plate 4, and the upper and lower combined cover plates 21 are used to press the magnetic core pressing plate 4 and the split magnetic core 5;

[0041] The outer surface of the outer shell 2 is provided with a downward pressure type guard plate 8, which is a split type guard plate and is tightly attached to the top and side of the outer shell 2;

[0042] An outer mounting plate 1 is provided on the circumferential side of the winding skeleton 3, and a filler 9 is provided on the inner wall of the outer mounting plate 1. The winding skeleton 3 and the winding wire 7 are both in contact with the filler 9, and there is a net friction-type squeezing effect between the side wall of the outer mounting plate 1 and the downward pressure guard plate 8; a mounting frame is provided on the outside of the outer mounting plate 1;

[0043] The elliptical design of the middle magnetic column can make full use of space, improve power density and reduce volume. The core material uses low-loss 96A material, and the eddy current magnetic column is reduced by changing the gap of the elliptical core. The cylindrical middle magnetic column on the top view is larger in diameter when coiled, and the coiled surface increases with the thickness of the winding stack. The elliptical EDX structure center magnetic column can increase the winding length of the coil layer and the outer wall of the magnetic column. There is no need to coil multiple layers to obtain more beneficial efficiency effects of magnetic flux. Compared with the original winding method, it has the characteristics of fewer coils, convenient stacking, centralized and efficient, and it is convenient to reduce the size of the device, which can be better used in trams.

[0044] The above description of the present invention is illustrative in combination with the accompanying drawings. It is obvious that the specific implementation of the present invention is not limited to the above-mentioned method. As long as such non-substantial improvements are made by adopting the method concept and technical solution of the present invention, or the concept and technical solution of the present invention are directly applied to other occasions without improvement, they are all within the scope of protection of the present invention.

Claims

1. A high power density LLC transformer, characterized by: The invention comprises a winding skeleton (3), a split magnetic core (5), and a winding wire (7); the winding skeleton (3) comprises an upper skeleton layer (32) and a lower skeleton layer (33); a slot gap (31) is provided between the upper skeleton layer (32) and the lower skeleton layer (33); the inner layer of the winding skeleton (3) is elliptical in a top view; the split magnetic core (5) is located inside the winding skeleton (3); the upper magnetic core located within the height interval of the upper skeleton layer (32) and the upper magnetic core located within the height interval of the lower skeleton layer (33) are separated from each other; and the winding wire (7) is coiled on the outside of the winding skeleton (3).

2. The high power density LLC transformer according to claim 1, characterized in that: The winding skeleton (3) comprises an elliptical through-tube wall and a plurality of winding discs, wherein the winding discs are fixed to the circumference of the elliptical barrel tube wall and arranged at intervals from top to bottom, and a terminal post (6) is provided on one side of the winding disc at the top layer, and the terminal post (6) is used to fix the outlet end of the winding wire (7).

3. The high power density LLC transformer according to claim 2, characterized in that: The number of the multi-layer winding discs is at least three, the upper skeleton layer (32) is located between the top winding disc and the middle winding disc, and the lower skeleton layer (33) is located between the bottom winding disc and the middle winding disc; A plurality of heat dissipation holes (34) are provided on each of the plurality of winding discs.

4. The high power density LLC transformer according to claim 2, characterized in that: The side walls of the upper frame layer (32) and the lower frame layer (33) are both provided with a plurality of vertical slot holes (35).

5. The high power density LLC transformer according to claim 1, characterized in that: The winding wire (7) includes an inner winding (71) and an outer winding (72), wherein the outer winding (72) is wound around the outside of the inner winding (71), and the winding wire (7) is respectively wound around the outer walls of the upper skeleton layer (32) and the lower skeleton layer (33).

6. The high power density LLC transformer according to claim 1, characterized in that: An outer shell (2) is provided on the outside of the winding skeleton (3), and the outer shell (2) includes upper and lower combined cover plates (21). A magnetic core pressing plate (4) is provided on the upper part of the split magnetic core (5), and the upper and lower combined cover plates (21) are used to press the magnetic core pressing plate (4) and the split magnetic core (5).

7. The high power density LLC transformer according to claim 6, characterized in that: A downward pressure type guard plate (8) is provided on the outside of the outer shell (2). The downward pressure type guard plate (8) is a split type guard plate and is closely attached to the top and side surfaces of the outer shell (2).

8. The high power density LLC transformer according to claim 7, characterized in that: An outer mounting plate (1) is provided on the peripheral side of the winding frame (3), a filler (9) is provided on the inner wall of the outer mounting plate (1), the winding frame (3) and the winding wire (7) are both in contact with the filler (9), and a net friction-type extrusion effect exists between the side wall of the outer mounting plate (1) and the downward pressure guard plate (8); and a mounting frame is provided on the outside of the outer mounting plate (1).

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