Novel transformer structure
By using a thermally conductive adhesive shell to wrap the magnetic core and coil in the transformer, and doping it with thermally conductive filler, the problem of poor heat dissipation in transformers is solved, achieving more efficient heat dissipation and lower material costs, and adapting to diverse installation needs.
Patent Information
- Application Number
- CN202422799717.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-18
- Publication Date
- 2025-10-28
- Estimated Expiration
- 2034-11-18
AI Technical Summary
In existing transformer structures, internal heat needs to be dissipated through two layers of material, resulting in poor heat dissipation and becoming a bottleneck for high-power, small-size, and low-cost designs.
The magnetic core and coil are wrapped in a thermally conductive adhesive shell. The thermally conductive adhesive is poured into a mold to form the thermally conductive adhesive shell, which directly dissipates the internal heat. Thermally conductive fillers are also mixed inside the thermally conductive adhesive shell to improve thermal conductivity and structural strength.
It improves heat dissipation, reduces product size and material costs, and enhances product stability and adaptability to meet the needs of different installation spaces.
Smart Images
Figure CN223486810U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of magnetic components technology, and in particular relates to a novel transformer structure. Background Technology
[0002] With the continuous development of on-board charger (OBC) technology, the market demand for high power, small size and low cost is becoming stronger. As one of the key components, magnetic components, especially the main transformer, have gained more and more recognition, research and attention. Magnetic components are also developing in a corresponding direction towards high power, small size and low cost.
[0003] Currently, achieving high power, small size, and low cost for magnetic components has become a bottleneck in their development due to the challenge of heat dissipation. The traditional approach involves creating a casing, placing the product inside, and then filling the casing with thermally conductive adhesive. This allows heat to be dissipated through two layers of material, resulting in relatively poor heat dissipation. Utility Model Content
[0004] The purpose of this utility model is to provide a new transformer structure to address the shortcomings of the existing technology, thereby solving the technical problem that the heat dissipation effect of the transformer is relatively poor because the heat inside the transformer has to be discharged through two layers of materials.
[0005] The objective of this utility model can be achieved through the following technical solutions:
[0006] A novel transformer structure includes a plastic base, a magnetic core, and a coil; the structure further includes:
[0007] The thermally conductive adhesive shell is formed by fitting a mold over the magnetic core and coil, and then pouring thermally conductive adhesive into the mold to cure it. The thermally conductive adhesive shell completely encloses the magnetic core and coil.
[0008] As a preferred embodiment of the above technical solution, the thermally conductive adhesive is an adhesive with high thermal conductivity, high fluidity, and high hardness after curing.
[0009] As a preferred embodiment of the above technical solution, the thermally conductive adhesive shell fills all the gaps between the magnetic core and the coil.
[0010] As a preferred embodiment of the above technical solution, the thermally conductive adhesive shell is doped with thermally conductive filler.
[0011] As a preferred embodiment of the above technical solution, a heat dissipation vent is detachably installed on the surface of the thermally conductive adhesive shell.
[0012] As a preferred embodiment of the above technical solution, the magnetic core and coil are fixed to the plastic base with glue after assembly.
[0013] The beneficial effects of this utility model are as follows:
[0014] 1. In this utility model, by filling the magnetic core and coil with thermally conductive adhesive and using a mold, the thermally conductive adhesive is cured to form a thermally conductive adhesive shell. The thermally conductive adhesive shell directly serves as the outer shell of the product, allowing the heat generated inside the product during operation to be directly dissipated through the thermally conductive adhesive shell. Compared with the traditional process, one shell material is reduced to conduct heat, thereby improving the heat dissipation effect.
[0015] 2. In this utility model, reducing the outer shell reduces the product volume, thus better adapting to the installation space and saving material costs; in addition, the thermally conductive adhesive shell is obtained by casting, so different shapes of thermally conductive adhesive shells can be made by using molds of different shapes according to different installation spaces or needs, so that the thermally conductive adhesive shell can be further adapted to the installation space.
[0016] 3. In this utility model, the thermally conductive adhesive shell is doped with thermally conductive filler, which can improve the thermal conductivity of the thermally conductive adhesive shell, thereby improving the heat dissipation effect; at the same time, the thermally conductive filler mixed in the thermally conductive adhesive shell can strengthen the structural strength of the thermally conductive adhesive shell, thereby improving the stability of the product. Attached Figure Description
[0017] Figure 1 This is a schematic diagram of the overall structure of this utility model;
[0018] Figure 2 This is a schematic diagram of the internal structure of this utility model;
[0019] Figure 3 This is a schematic diagram of the exploded structure of this utility model.
[0020] In the picture:
[0021] 1. Plastic base; 2. Magnetic core; 3. Coil; 4. Thermally conductive adhesive shell; 5. Thermally conductive filler; 6. Heat sink. Detailed Implementation
[0022] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present utility model.
[0023] like Figures 1-3 As shown, a novel transformer structure includes a plastic base 1, a magnetic core 2, and a coil 3. The structure also includes:
[0024] The thermally conductive adhesive shell 4 is formed by fitting a mold over the magnetic core 2 and coil 3, and then pouring thermally conductive adhesive into the mold to cure it. The thermally conductive adhesive shell 4 completely encloses the magnetic core 2 and coil 3.
[0025] In one embodiment, the thermally conductive adhesive is an adhesive with high thermal conductivity, high fluidity, and high hardness after curing. It can be an organosilicon potting compound, such as Zhaoke TIS thermally conductive potting compound, which has a thermal conductivity of 1.0W-2.8W / mK. It also has good electrical insulation properties, moisture resistance, dust resistance, and corrosion resistance. This potting compound has low viscosity, is easy to flow and fill, and forms a tight encapsulation layer after curing, with high hardness. Pins can be formed directly from the beginning and end of the coil 3, or pins of a specific shape can be made on the plastic base 1. Then, the coil 3 is connected to the pins on the plastic base 1 through special processes such as welding.
[0026] The potting compound can form the desired shape on the product surface. Then, it connects to the client's cooling system, allowing heat dissipated from the product's interior to be quickly transferred to the cooling system, thus cooling the product.
[0027] In practical applications, according to the installation requirements of different environments, the coil 3 is made into a special shape and installed on the special-shaped magnetic core 2 through a special arrangement, so that the coil 3 and the magnetic core 2 are combined. The combination of the magnetic core 2 and the coil 3 is fixed to the plastic base 1 with glue. Then, a mold is placed outside the combination of the magnetic core 2 and the coil 3, and thermally conductive glue is poured into the mold to form a cured glue layer of the required thickness and shape, thus obtaining the thermally conductive glue shell 4. In this way, a layer of potting glue "shell" is formed on the surface of the product, so that the heat generated inside the product during operation can be directly dissipated through the thermally conductive glue shell 4. Compared with the traditional process, one shell material is reduced to conduct heat, thereby improving the heat dissipation effect.
[0028] Reducing the size of the outer casing reduces the product's volume, allowing it to better adapt to installation space and saving on material costs. Furthermore, the thermally conductive adhesive outer casing 4 is obtained through casting, enabling the production of different shapes of thermally conductive adhesive outer casing 4 using molds of different shapes to meet different installation spaces or requirements, thus further adapting the thermally conductive adhesive outer casing 4 to the installation space.
[0029] Furthermore, the thermally conductive adhesive shell 4 fills all the gaps between the magnetic core 2 and the coil 3.
[0030] In practical applications, before the thermally conductive adhesive shell 4 is cured, the thermally conductive adhesive fills every gap between the magnetic core 2 and the coil 3. On the one hand, it can effectively conduct the heat generated inside to the outside, and on the other hand, it can effectively prevent air bubbles from existing inside the cured thermally conductive adhesive shell 4. The internal heat may expand and deform due to the presence of air bubbles, thus affecting the heat dissipation effect. In severe cases, it may cause the thermally conductive adhesive shell 4 to explode, thereby damaging other surrounding components.
[0031] Furthermore, the thermally conductive adhesive shell 4 is doped with thermally conductive filler 5.
[0032] In one embodiment, the thermally conductive filler 5 may be alumina, which has a high thermal conductivity and good electrical insulation properties.
[0033] In practical applications, the thermally conductive filler 5 can improve the thermal conductivity of the thermally conductive adhesive shell 4, thereby improving the heat dissipation effect. At the same time, the thermally conductive filler 5 mixed in the thermally conductive adhesive shell 4 can strengthen the structural strength of the thermally conductive adhesive shell 4, thereby improving the stability of the product.
[0034] Furthermore, a heat sink 6 is detachably installed on the surface of the thermally conductive adhesive housing 4.
[0035] In practical application, the thermally conductive adhesive shell 4 has a pre-reserved slot during casting, and there is a plug on the heat dissipation radiator 6. By inserting the plug into the slot, the heat dissipation radiator 6 can be detached and installed. The heat dissipation radiator 6 can further improve the heat dissipation effect of the product. At the same time, the heat dissipation radiator 6 can be connected to an external cooling system, so that the heat dissipated from the inside of the product can be quickly transferred to the cooling system, thereby achieving rapid cooling of the product.
[0036] Working principle: In use, the magnetic core 2 and coil 3 are assembled and fixed to the plastic base 1 with glue. Then, a mold is placed outside the assembly of the magnetic core 2 and coil 3, and thermally conductive glue is poured into the mold to fill every gap between the magnetic core 2 and coil 3, thereby forming a cured glue layer of the required thickness and shape, resulting in the thermally conductive glue shell 4. The thermally conductive glue shell 4 directly serves as the outer shell of the product. Compared with the traditional process, it reduces the heat conduction of one shell material, thereby improving the heat dissipation effect.
[0037] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed utility model.
Claims
1. A novel transformer structure, comprising a plastic base (1), a magnetic core (2), and a coil (3), characterized in that, The structure also includes: The thermally conductive adhesive shell (4) is formed by placing a mold over the magnetic core (2) and coil (3) and pouring thermally conductive adhesive into the mold to cure it. The thermally conductive adhesive shell (4) completely encloses the magnetic core (2) and coil (3).
2. The novel transformer structure according to claim 1, characterized in that, The thermally conductive adhesive is an adhesive with high thermal conductivity, high fluidity, and high hardness after curing.
3. The novel transformer structure according to claim 2, characterized in that, The thermally conductive adhesive shell (4) fills all the gaps between the magnetic core (2) and the coil (3).
4. The novel transformer structure according to claim 1, characterized in that, The thermally conductive adhesive shell (4) is doped with thermally conductive filler (5).
5. The novel transformer structure according to claim 1, characterized in that, A heat sink (6) is detachably installed on the surface of the thermally conductive adhesive shell (4).
6. The novel transformer structure according to claim 1, characterized in that, The magnetic core (2) and coil (3) are fixed to the plastic base (1) with glue after assembly.