Magnetic combined transformer convenient to produce and assemble
By integrating the resonant inductor and transformer onto a fixed base and placing an air gap between them, the problems of large PCB size and high production cost in existing technologies are solved, achieving high-frequency saturation of the transformer and reducing production costs.
Patent Information
- Application Number
- CN202520229897.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-02-13
- Publication Date
- 2025-12-09
- Estimated Expiration
- 2035-02-13
AI Technical Summary
The transformers in existing on-board chargers use a separate transformer plus a resonant inductor in a magnetically integrated manner, which increases the PCB size and production cost.
Design a magnetic combination transformer that is easy to manufacture and assemble. Integrate the resonant inductor and the transformer on a fixed base and set an air gap between the resonant inductor and the transformer. Adjust the size of the air gap to meet different inductance requirements.
It achieves better high-frequency saturation of the transformer, has a small overall size, reduces production costs, and facilitates production and assembly.
Smart Images
Figure CN223651237U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of transformer technology, specifically to a magnetic combination transformer that is easy to manufacture and assemble. Background Technology
[0002] An on-board charger (OBC) is an indispensable component of modern electric vehicles. It's a device that converts external AC power (usually household AC or AC from public charging stations) into DC power to safely and efficiently charge the electric vehicle's battery. On-board chargers are typically installed inside the electric vehicle and work closely with the vehicle's battery management system (BMS) to ensure the stability of the charging process and the safety of the battery.
[0003] The workflow of an on-board charger can be roughly divided into the following steps: First, it receives AC power from an external source through the vehicle's charging port; next, it uses an internal rectifier and inverter to convert the AC power into DC power; then, according to the instructions of the battery management system, it precisely adjusts the charging current and voltage to adapt to different battery states and needs; finally, it safely delivers the converted DC power to the power battery for charging. The entire process requires strict control of parameters such as temperature, current, and voltage to prevent the battery from overheating, overcharging, or being damaged.
[0004] The transformer in existing on-board chargers uses a separate transformer plus a resonant inductor in a magnetically integrated manner, which has the problems of increasing PCB size and high production cost. Utility Model Content
[0005] The purpose of this invention is to provide a magnetic combination transformer that is easy to manufacture and assemble, thereby solving the above-mentioned technical problems.
[0006] The objective of this utility model can be achieved through the following technical solutions:
[0007] A magnetic combination transformer that is easy to manufacture and assemble includes a fixed base. A resonant inductor core and a transformer core are arranged side-by-side on the upper end of the fixed base, separated by an air gap. The resonant inductor core has a U-shaped structure, with inductor enameled wire wound around both parallel ends of the U-shaped structure. The transformer core consists of two symmetrically distributed U-shaped structures forming a loop structure, with transformer enameled wire wound around both opposite ends of the loop structure. A copper plate is provided as an outer cover for the transformer core, and the copper plate is fixedly connected to the fixed base.
[0008] Preferably, the fixed base includes a base plate, the base plate is provided with a side plate on its outer periphery, and the base plate is provided with a plurality of wiring holes for wire connection.
[0009] Preferably, the base plate is provided with a plurality of cavity grooves.
[0010] Preferably, a support platform for supporting the transformer core is fixedly provided at the middle of the upper end of the base plate.
[0011] Preferably, a limiting stop for limiting the transformer core is fixedly provided on the support platform.
[0012] Preferably, the upper end of the base plate is fixedly provided with a core guide post for limiting the installation of the resonant inductor core.
[0013] Preferably, the upper end of the base plate is provided with a clearance groove for avoiding inductor enameled wires and transformer enameled wires.
[0014] Preferably, the copper sheet includes an outer baffle, an upper connecting plate is fixedly provided at the upper end of the outer baffle, and a vertically downward inner insert plate is fixedly provided on the side of the upper connecting plate away from the outer baffle. The inner insert plate is provided with connecting holes for installing the copper sheet.
[0015] Preferably, a connecting plate is fixedly provided at the lower end of both the outer baffle and the inner insert plate, and a copper plate slot that mates with the connecting plate is provided on the base plate.
[0016] Preferably, the thickness of the air gap pad is proportional to the magnitude of the resonant inductance.
[0017] As a further embodiment of this utility model:
[0018] The beneficial effects of this utility model are:
[0019] (1) Integrate the resonant inductor and the transformer on a fixed base, and set an air gap between the resonant inductor and the transformer. By adjusting the size of the air gap, the required inductance can be achieved to meet different design requirements.
[0020] (2) The transformer of this utility model has better high-frequency saturation and small overall size. This magnetic integrated transformer is easy to manufacture and assemble, reducing production costs. Attached Figure Description
[0021] The present invention will be further described below with reference to the accompanying drawings.
[0022] Figure 1 This is a schematic diagram of the overall structure of a magnetic combined transformer that is easy to manufacture and assemble according to this utility model.
[0023] Figure 2 This is an isometric structural diagram of a magnetic combination transformer that is easy to manufacture and assemble according to this utility model;
[0024] Figure 3 This is a three-dimensional structural diagram of the present invention involving the removal of a set of copper plates;
[0025] Figure 4 This is a three-dimensional structural diagram of the fixed base of this utility model;
[0026] Figure 5 This is a three-dimensional structural diagram of the copper sheet of this utility model.
[0027] In the diagram: 10. Fixed base; 11. Base plate; 12. Side plate; 13. Cavity groove; 14. Copper plate slot; 15. Support platform; 16. Limiting stop; 17. Magnetic core guide post; 18. Wiring hole; 19. Clearance groove; 20. Resonant inductor core; 30. Inductor enameled wire; 40. Air gap pad; 50. Transformer core; 60. Transformer enameled wire; 70. Copper plate; 71. Outer baffle; 72. Upper connecting plate; 73. Inner insert plate; 74. Connecting insert plate; 75. Connecting hole. Detailed Implementation
[0028] The technical solutions of the embodiments of the present invention / utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention / utility model, and not all embodiments. Based on the embodiments of the present invention / utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present invention / utility model.
[0029] In the description of this invention / utility model, it should be understood that the terms "upper," "lower," "left," "right," etc., indicating orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or a specific orientational structure and operation. Therefore, they should not be construed as limitations on this utility model. Furthermore, "first" and "second" are only for descriptive purposes and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, unless otherwise stated, "multiple" means two or more.
[0030] In the description of this invention / utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.
[0031] Please see Figures 1-5 As shown, this utility model is a magnetic combination transformer that is easy to manufacture and assemble. It includes a fixed base 10. A resonant inductor core 20 and a transformer core 50 are arranged side by side on the upper end of the fixed base 10. The resonant inductor core 20 and the transformer core 50 are separated by an air gap 40. The resonant inductor core 20 has a U-shaped structure, and inductor enameled wire 30 is wound around both parallel ends of the U-shaped structure. The transformer core 50 is a loop structure composed of two sets of symmetrically distributed U-shaped structures. Transformer enameled wire 60 is wound around both opposite ends of the loop structure. A copper plate 70 is covered on the outside of the transformer core 50, and the copper plate 70 is fixedly connected to the fixed base 10.
[0032] In an optional embodiment, the fixed base 10 includes a base plate 11, the base plate 11 is provided with a side panel 12 on its outer periphery, and the base plate 11 is provided with a plurality of wiring holes 18 for wire connection.
[0033] It should be noted that the side panel 12 serves to limit the installation of the resonant inductor core 20 and the transformer core 50, ensuring the stability of the core installation. The wiring hole 18 facilitates the through-hole connection of wires.
[0034] In an optional embodiment, the base plate 11 is provided with a plurality of cavity grooves 13.
[0035] It should be noted that the social self-cavity groove 13 effectively reduces the overall weight of the fixed base 10, while also reducing the amount of material used.
[0036] In an optional embodiment, a support platform 15 for supporting the transformer core 50 is fixedly disposed at the upper center of the base plate 11.
[0037] It should be noted that the support platform 15 provides support for the installation of the transformer core 50, creating a certain gap between the transformer core 50 and the base plate 11. This ensures the winding of the transformer enameled wire 60 and improves the heat dissipation performance of the transformer core 50, thereby extending the service life of the transformer.
[0038] In an optional embodiment, a limiting stop 16 for limiting the transformer core 50 is fixedly provided on the support platform 15.
[0039] It should be noted that the limit stop 16 is used to limit the installation of the transformer core 50, thereby ensuring the stability of the installation of the transformer core 50.
[0040] In an optional embodiment, a core guide post 17 for limiting the installation of the resonant inductor core 20 is fixedly provided on the upper end of the base plate 11.
[0041] It should be noted that the magnetic core guide post 17 serves to limit the installation of the resonant inductor core 20, thereby ensuring the stability of the installation of the resonant inductor core 20.
[0042] In an optional embodiment, the upper end of the base plate 11 is provided with a clearance groove 19 for avoiding the inductor enameled wire 30 and the transformer enameled wire 60.
[0043] It should be noted that the clearance groove 19 serves to avoid obstacles during the installation of enameled wire.
[0044] In an optional embodiment, the copper sheet 70 includes an outer baffle 71, an upper connecting plate 72 is fixedly disposed on the upper end of the outer baffle 71, and a vertically downward inner insert plate 73 is fixedly disposed on the side of the upper connecting plate 72 away from the outer baffle 71. The inner insert plate 73 is provided with a connecting hole 75 for mounting the copper sheet 70.
[0045] It should be noted that the copper plate 70 covers the transformer core 50 and the wound transformer enameled wire 60, thereby protecting the enameled wire.
[0046] In an optional embodiment, a connecting plate 74 is fixedly provided at the lower end of both the outer baffle 71 and the inner insert plate 73, and a copper plate slot 14 that cooperates with the connecting plate 74 is provided on the base plate 11.
[0047] It should be noted that the connection between the connecting plate 74 and the copper plate slot 14 ensures stable installation of the plate 70.
[0048] In an optional embodiment, the thickness of the air gap pad 40 is proportional to the magnitude of the resonant inductance.
[0049] It should be noted that the addition of the air gap 40 can prevent magnetic saturation of the magnetic core under large AC signals or DC bias. Magnetic saturation leads to a decrease in the permeability of the magnetic core, thus affecting the stability of the inductance. By adjusting the size of the air gap 40, the required inductance can be achieved to meet different design requirements.
[0050] The working principle of this utility model is as follows: A transformer is formed by a transformer core 50 and a transformer enameled wire 60, which consists of two or more windings wound on the same core. When alternating current passes through the primary winding, an alternating magnetic field is generated in the core, which induces a voltage in the secondary winding. By changing the turns ratio of the primary and secondary windings, the voltage can be boosted or bucked. A resonant inductor is formed by a resonant inductor core 20 and an inductor enameled wire 30. The resonant inductor and capacitor together form a resonant circuit, which can resonate at a specific frequency, thus being used for applications such as filtering, oscillation, and frequency selection. The quality factor of the resonant inductor is usually high to ensure the performance of the resonant circuit. The resonant inductor and transformer are integrated on a fixed base 10, and an air gap 40 is set between the resonant inductor and the transformer. By adjusting the size of the air gap 40, the required inductance can be achieved to meet different design requirements.
[0051] The above description provides a detailed account of one embodiment of the present invention. However, this description is merely a preferred embodiment and should not be construed as limiting the scope of the present invention. All equivalent variations and improvements made within the scope of the claims of the present invention should still fall within the patent coverage of the present invention.
Claims
1. A magnetic combination transformer that is easy to manufacture and assemble, characterized in that, The system includes a fixed base (10), on which a resonant inductor core (20) and a transformer core (50) are arranged side by side. The resonant inductor core (20) and the transformer core (50) are separated by an air gap pad (40). The resonant inductor core (20) has a U-shaped structure, and inductor enameled wire (30) is wound around both parallel ends of the U-shaped structure. The transformer core (50) is a loop structure composed of two sets of symmetrically distributed U-shaped structures, and transformer enameled wire (60) is wound around both opposite ends of the loop structure. The transformer core (50) is covered with a copper plate (70), which is fixedly connected to the fixed base (10).
2. The magnetic combination transformer according to claim 1, characterized in that, The fixed base (10) includes a base plate (11), and a side plate (12) is provided on the outer periphery of the base plate (11). The base plate (11) is provided with a plurality of wiring holes (18) for wire connection.
3. A magnetic combination transformer that is easy to manufacture and assemble according to claim 2, characterized in that, The base plate (11) is provided with several cavity grooves (13).
4. A magnetic combination transformer that is easy to manufacture and assemble according to claim 2, characterized in that, A support platform (15) for supporting the transformer core (50) is fixedly installed at the middle of the upper end of the base plate (11).
5. A magnetic combination transformer that is easy to manufacture and assemble according to claim 4, characterized in that, A limiting stop (16) for limiting the transformer core (50) is fixedly installed on the support platform (15).
6. A magnetic combination transformer that is easy to manufacture and assemble according to claim 2, characterized in that, The upper end of the base plate (11) is fixedly provided with a core guide post (17) for limiting the installation of the resonant inductor core (20).
7. A magnetic combination transformer that is easy to manufacture and assemble according to claim 2, characterized in that, The upper end of the base plate (11) is provided with a clearance groove (19) for avoiding the inductor enameled wire (30) and the transformer enameled wire (60).
8. A magnetic combination transformer that is easy to manufacture and assemble according to claim 2, characterized in that, The copper sheet plate (70) includes an outer baffle (71), an upper connecting plate (72) is fixedly provided at the upper end of the outer baffle (71), and a vertically downward inner insert plate (73) is fixedly provided on the side of the upper connecting plate (72) away from the outer baffle (71). The inner insert plate (73) is provided with a connecting hole (75) for installing the copper sheet plate (70).
9. A magnetic combination transformer that is easy to manufacture and assemble according to claim 8, characterized in that, The lower ends of the outer baffle (71) and the inner insert plate (73) are both fixedly provided with connecting insert plates (74), and the base plate (11) is provided with copper plate slots (14) that cooperate with the connecting insert plates (74).
10. A magnetic combination transformer that is easy to manufacture and assemble according to claim 1, characterized in that, The thickness of the air gap pad (40) is proportional to the magnitude of the resonant inductance.