Power module

Abstract

The utility model provides a power module which comprises an insulating plate, a transformer and a first shielding layer, the insulating plate comprises a flat plate part, the transformer comprises a magnetic core and a first winding wound on the magnetic core, the first winding comprises a first part and a second part which are electrically connected, the first part is located on the side, away from the magnetic core, of the insulating plate, and the second part is located on the side, away from the magnetic core, of the insulating plate. The second part is arranged in the insulating plate in a penetrating manner; the first shielding layer is at least arranged on one side, facing the magnetic core, of the insulating plate; in a first reference plane parallel to the flat plate part, the projection of the magnetic core is located in the projection range of the first shielding layer. The first shielding layer is arranged on the side, facing the magnetic core, of the insulating plate, and the projection of the magnetic core is located in the projection range of the first shielding layer, so that the air field intensity around the magnetic core can be reduced through the first shielding layer, the insulating service life is prolonged, and the product reliability is improved.

Description

Technical Field

[0001] This application relates to the field of electrical equipment technology, and more particularly to a power module. Background Technology

[0002] A power module is a combination of multiple electronic devices into a single module according to certain functions. It is mainly used to control the power output and power conversion in circuits and is widely used in various electronic devices.

[0003] In the related technical solutions, the power module includes a housing and a transformer and voltage power devices disposed inside the housing. An insulating plate is provided inside the housing. The transformer includes a magnetic core, a first winding and a second winding. The first winding and the second winding are respectively connected to the corresponding voltage power devices. At least two of the magnetic core, the first winding and the second winding are wound on the insulating plate. The magnetic core, the first winding and the second winding are insulated from each other by the insulating plate.

[0004] However, with the solution using the relevant technology, a large electric field will be generated in the air between the magnetic core, the first winding, and the second winding. When there are sharp burrs on the edge of the magnetic core, discharge may occur, thus affecting the insulation life. Utility Model Content

[0005] In order to overcome the above-mentioned defects in related technologies, the purpose of this application is to provide a power module that can reduce the air field strength around the magnetic core, extend the insulation life, and improve the reliability of the product.

[0006] This application provides a power module, including:

[0007] Insulating board, including flat plate portion;

[0008] A transformer includes a magnetic core and a first winding wound on the magnetic core. The first winding includes a first portion and a second portion that are electrically connected. The first portion is located on the side of the insulating plate opposite to the magnetic core, and the second portion passes through the insulating plate.

[0009] A first shielding layer is provided at least on the side of the insulating plate facing the magnetic core;

[0010] Within a first reference plane parallel to the flat plate, the projection of the magnetic core lies within the projection range of the first shielding layer.

[0011] In one possible implementation, the insulating plate further includes a protrusion and a connecting bridge. The flat plate is parallel to the first reference plane formed by the first direction and the second direction. The protrusion and / or the connecting bridge protrude from the flat plate along a third direction, thereby forming an insulating cavity. At least a portion of the magnetic core is disposed within the insulating cavity. The first portion is located on the side of the protrusion facing away from the insulating cavity, and the second portion is located within the connecting bridge. The transformer further includes a second winding, which is directly wound on the magnetic core.

[0012] The magnetic core includes a first vertical column and a second vertical column arranged opposite to each other, and a first horizontal column and a second horizontal column arranged opposite to each other, with the first vertical column, the first horizontal column, the second vertical column and the second horizontal column connected end to end in sequence.

[0013] Wherein, the first direction, the second direction, and the third direction are perpendicular to each other.

[0014] In one possible implementation, within a second reference plane parallel to the first direction and the third direction, the magnetic core includes a first end point, a second end point, a third end point, and a fourth end point; along the third direction, the first end point and the second end point are respectively located at the two ends of the magnetic core near the protrusion, and the third end point and the fourth end point are respectively located at the two ends of the magnetic core away from the protrusion; along the first direction, the first shielding layer includes a first shielding end and a second shielding end, the first shielding end being near the first end point and the second shielding end being near the second end point.

[0015] In one possible implementation, within a third reference plane parallel to the second direction and the third direction, the magnetic core includes a fifth endpoint, a sixth endpoint, a seventh endpoint, and an eighth endpoint; along the third direction, the fifth and sixth endpoints are located at the two ends of the magnetic core near the protrusion, and the seventh and eighth endpoints are located at the two ends of the magnetic core away from the protrusion; along the second direction, the first shielding layer includes a third shielding end and a fourth shielding end, the third shielding end being near the fifth endpoint and the fourth shielding end being near the sixth endpoint.

[0016] In one possible implementation, along the first direction, the distance between the first shielding end and the first endpoint is H1, and along the third direction, the distance between the third endpoint and the protrusion is D1; ​​along the first direction, the distance between the second shielding end and the second endpoint is H2, and along the third direction, the distance between the fourth endpoint and the protrusion is D2, wherein H1 / D1 and H2 / D2 satisfy a first threshold greater than or equal to it and a second threshold less than or equal to it.

[0017] In one possible implementation, the first threshold is 1.5 and the second threshold is 3.

[0018] In one possible implementation, along the second direction, the distance between the third shielding end and the fifth endpoint is H3; along the third direction, the distance between the seventh endpoint and the protrusion is D3; along the second direction, the distance between the fourth shielding end and the sixth endpoint is H4; along the third direction, the distance between the eighth endpoint and the protrusion is D4, wherein H3 / D3 and H4 / D4 satisfy a third threshold greater than or equal to it and a fourth threshold less than or equal to it.

[0019] In one possible implementation, the third threshold is 1.5 and the fourth threshold is 3.

[0020] In one possible implementation, the projection of the first shielding layer lies within the projection range of the insulating plate in a plane parallel to the first reference plane.

[0021] In one possible implementation, the first shielding layer is disposed on one side of the flat plate portion along the third direction, on the surface of the connecting bridge, and on the side of the protrusion facing the magnetic core.

[0022] In one possible implementation, a second shielding layer is further included, disposed on the side of the insulating plate facing the magnetic core. The second shielding layer is connected to the first shielding layer and surrounds the outer periphery of the first shielding layer. The resistivity of the second shielding layer is greater than that of the first shielding layer.

[0023] In one possible implementation, a third shielding layer is further included, disposed on the side of the insulating plate facing the first portion, such that the projection of the first portion lies within the projection range of the third shielding layer in a plane parallel to the first reference plane.

[0024] In one possible implementation, a fourth shielding layer is further included, disposed on the side of the insulating plate facing the first portion. The fourth shielding layer is connected to the third shielding layer and surrounds the outer periphery of the third shielding layer. The resistivity of the fourth shielding layer is greater than that of the third shielding layer.

[0025] In one possible implementation, along the third direction, the distance between the connecting bridge and the flat plate is zero, the protrusion protrudes from the flat plate, the first cross post is located inside the insulating cavity, the second cross post is located outside the insulating cavity, and the second winding is wound on the first cross post.

[0026] In one possible implementation, along the third direction, the distance between the protrusion and the flat plate is zero, the connecting bridge protrudes from the flat plate, the first cross post is located inside the insulating cavity, the second cross post is located outside the insulating cavity, and the second winding is wound on the first cross post.

[0027] In one possible implementation, the insulating plate further includes a partition plate disposed within the insulating cavity. The partition plate connects the protrusion and the connecting bridge, and divides the insulating cavity into a first sub-insulating cavity and a second sub-insulating cavity. The first crossbar is located within the first sub-insulating cavity, and the second crossbar is located within the second sub-insulating cavity.

[0028] In one possible implementation, the transformer includes two first windings and two second windings, with the two first windings respectively wound around the outside of the two second windings, the first portions of the two first windings respectively disposed on the side of the protrusion away from the insulating cavity, the second portions of the two first windings respectively disposed within the partition plate and the connecting bridge, and the two second windings respectively wound on the first cross post and the second cross post.

[0029] In one possible implementation, along the third direction, the distance between the protrusion and the flat plate is zero, and the connecting bridge protrudes from the flat plate.

[0030] In one possible implementation, along the third direction, the distance between the connecting bridge and the flat plate is zero, and the protrusion protrudes from the flat plate.

[0031] This application provides a power module including an insulating plate, a transformer, and a first shielding layer. The insulating plate includes a flat plate portion, and the transformer includes a magnetic core and a first winding wound on the magnetic core. The first winding includes a first portion and a second portion electrically connected. The first portion is located on the side of the insulating plate away from the magnetic core, and the second portion passes through the insulating plate. The first shielding layer is at least disposed on the side of the insulating plate facing the magnetic core. In a first reference plane parallel to the flat plate portion, the projection of the magnetic core lies within the projection range of the first shielding layer. By providing a first shielding layer on the side of the insulating plate facing the magnetic core, and ensuring that the projection of the magnetic core lies within the projection range of the first shielding layer, this application can reduce the air field strength around the magnetic core, extend the insulation life, and improve the reliability of the product. Attached Figure Description

[0032] To more clearly illustrate the technical solutions in the embodiments or related technologies of this application, the accompanying drawings used in the description of the embodiments or related technologies will be briefly introduced below. Obviously, the accompanying drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0033] Figure 1 A simplified structural diagram of a power module provided in one embodiment of this application;

[0034] Figure 2 for Figure 1 Side view;

[0035] Figure 3 for Figure 2 AA section view;

[0036] Figure 4 for Figure 2 BB section view;

[0037] Figure 5 A simplified structural diagram of a power module provided in another embodiment of this application;

[0038] Figure 6 for Figure 5 Side view;

[0039] Figure 7 for Figure 6 AA section view;

[0040] Figure 8 for Figure 6 BB section view;

[0041] Figure 9 A simplified structural diagram of a power module provided in another embodiment of this application;

[0042] Figure 10 for Figure 9 Side view;

[0043] Figure 11 for Figure 10 AA section view;

[0044] Figure 12 for Figure 10 BB section view;

[0045] Figure 13 A simplified structural diagram of a power module provided in another embodiment of this application;

[0046] Figure 14 for Figure 13 Side view;

[0047] Figure 15 for Figure 14 AA section view;

[0048] Figure 16 for Figure 14 BB cross-sectional view.

[0049] Figure label:

[0050] 100 - Insulating plate; 110 - Flat plate; 120 - Protrusion; 130 - Connecting bridge; 150 - Separator;

[0051] 210 - Magnetic core; 201 - First end point; 202 - Second end point; 203 - Third end point; 204 - Fourth end point; 205 - Fifth end point; 206 - Sixth end point; 207 - Seventh end point; 208 - Eighth end point; 211 - First upright post; 212 - Second upright post; 213 - First horizontal post; 214 - Second horizontal post;

[0052] 220 - First winding; 221 - First section; 222 - Second section;

[0053] 230 - Second winding;

[0054] 500 - First shielding layer; 501 - First shielding end; 502 - Second shielding end; 503 - Third shielding end; 504 - Fourth shielding end;

[0055] 600 - Third shielding layer;

[0056] X - First direction; Y - Second direction; Z - Third direction. Detailed Implementation

[0057] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are some embodiments of this application, but not all embodiments.

[0058] Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without inventive effort are within the scope of protection of this application. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0059] As described in the background section, in the power modules of related technologies, a large electric field is generated between the magnetic core, the first winding, and the second winding. When there are sharp burrs on the edge of the magnetic core, discharge may occur, thereby affecting the insulation life.

[0060] In view of this, the embodiments of this application aim to provide a power module that, by providing a first shielding layer on the side of the insulating plate facing the magnetic core, and with the projection of the magnetic core located within the projection range of the first shielding layer, can reduce the air field strength around the magnetic core, extend the insulation life, and improve the reliability of the product.

[0061] The embodiments of this application will now be described in detail with reference to the accompanying drawings, so that those skilled in the art can gain a more detailed understanding of the content of this application. In the description of the embodiments of this application, the first direction X, the second direction Y, and the third direction Z are three different directions in three-dimensional space. For example, the first direction X, the second direction Y, and the third direction Z can be perpendicular to each other.

[0062] The plane parallel to the first direction X and the second direction Y is the first reference plane; the plane parallel to the first direction X and the third direction Z is the second reference plane; and the plane parallel to the second direction Y and the third direction Z is the third reference plane.

[0063] Please refer to Figures 1-16 This embodiment provides a power module, including:

[0064] Insulating board 100, which may be formed of insulating material.

[0065] The transformer includes a magnetic core 210 and at least one first winding 220 and at least one second winding 230 wound on the magnetic core 210. The first winding 220 includes a first portion 221 and a second portion 222 electrically connected. The first portion 221 is located on the side of an insulating plate 100 opposite to the magnetic core 210, and the second portion 222 passes through the insulating plate 100. One of the first winding 220 and the second winding 230 is a high-voltage winding, and the other is a low-voltage winding. A high-voltage power device is provided on one side of the insulating plate 100, and a low-voltage power device is provided on the other side. One of the first winding 220 and the second winding 230 is electrically connected to the high-voltage power device, and the other is electrically connected to the low-voltage power device.

[0066] A first shielding layer 500 is disposed on the side of the insulating plate 100 facing the magnetic core 210. Exemplarily, the first shielding layer 500 is a semi-conductive layer, and the material of the first shielding layer 500 includes graphene, carbon black, coatings doped with conductive particles such as graphene or carbon black, or it can be a thin film filled with conductive particles. In a plane parallel to the first reference plane, the projection of the magnetic core 210 lies within the projection range of the first shielding layer 500; that is, the entire projection of the magnetic core 210 falls completely within the projection range of the first shielding layer 500, thereby achieving electromagnetic shielding of the magnetic core 210 using the first shielding layer 500.

[0067] It is understood that in this embodiment, by providing a first shielding layer 500 on the side of the insulating plate 100 facing the magnetic core 210, and with the projection of the magnetic core 210 located within the projection range of the first shielding layer 500, the first shielding layer 500 can be used to reduce the air field strength around the magnetic core 210, extend the insulation life, improve the reliability of the product, and also reduce the size of the insulation layer.

[0068] In this embodiment, the insulating plate 100 includes a flat plate portion 110, a protrusion portion 120, and a connecting bridge 130. The flat plate portion 110 is parallel to a first reference plane. The protrusion portion 120 and / or the connecting bridge 130 protrude from the flat plate portion 110 along a third direction Z, thereby forming an insulating cavity. At least a portion of the magnetic core 210 is disposed within the insulating cavity. In this embodiment, at least one of the protrusion portion 120 and the connecting bridge 130 may protrude relative to the flat plate portion 110. For example, as shown... Figure 1 and Figure 9 As shown, the connecting bridge 130 protrudes relative to the flat plate portion 110, while the protruding portion 120 does not protrude, and the protruding portion 120 and the flat plate portion 110 are located in the same plane. Figure 5 and Figure 13 As shown, the protrusion 120 protrudes relative to the flat plate 110, while the connecting bridge 130 does not protrude. The connecting bridge 130 and the flat plate 110 are located in the same plane. In other possible embodiments, both the protrusion 120 and the connecting bridge 130 may protrude relative to the flat plate 110. It is understood that in this embodiment, the protrusion 120 and the connecting bridge 130 are merely names for two different parts of the insulating plate 100, and the text does not indicate their specific structure.

[0069] Further, the first portion 221 of the first winding 220 is located on the surface of the protrusion 120 or passes through the protrusion 120. For example, the first portion 221 is located on the side of the insulating plate 100 away from the magnetic core 210. In this case, the first portion 221 can be located on the surface of the protrusion 120, or a portion of the first portion 221 can be embedded in the protrusion 120, or the first portion 221 can pass through the protrusion 120. When the first portion 221 passes through the protrusion 120, the structure of the protrusion 120 and the structure of the connecting bridge 130 can be the same. The second portion 222 is located within the connecting bridge 130; that is, the second portion 222 passes through the connecting bridge 130. The second winding 230 is directly wound on the magnetic core 210; for example, the second winding 230 can be located on the magnetic core 210 inside the insulating cavity or on the magnetic core 210 outside the insulating cavity.

[0070] The magnetic core 210 of this embodiment includes a first column 211 and a second column 212 arranged opposite to each other, and a first column 213 and a second column 214 arranged opposite to each other. The first column 211, the first column 213, the second column 212 and the second column 214 are connected end to end in sequence.

[0071] It is understood that the power module in this embodiment can be configured with different structures according to specific needs.

[0072] In some possible implementations, such as Figures 1-4 As shown, along the third direction Z, the distance between the protrusion 120 and the flat plate 110 is zero, meaning the protrusion 120 and the flat plate 110 are located in the same plane, and the connecting bridge 130 protrudes from the flat plate 110. Along the second direction Y, the height of the first horizontal post 213 is greater than the height of the insulating cavity. The first horizontal post 213 passes through the insulating cavity, with a portion inside the cavity and another portion outside. The second horizontal post 214 is located outside the insulating cavity, and the second winding 230 is wound around the first horizontal post 213.

[0073] In some possible implementations, such as Figures 5-8 As shown, along the third direction Z, the distance between the connecting bridge 130 and the flat plate 110 is zero, meaning the connecting bridge 130 and the flat plate 110 are located in the same plane, and the protrusion 120 protrudes from the flat plate 110. Along the second direction Y, the height of the first horizontal post 213 is greater than the height of the insulating cavity. The first horizontal post 213 passes through the insulating cavity, with a portion of it located inside the insulating cavity and the other portion outside. The second horizontal post 214 is located outside the insulating cavity, and the second winding 230 is wound on the first horizontal post 213.

[0074] In some possible implementations, such as Figures 9-12 As shown, along the third direction Z, the distance between the protrusion 120 and the flat plate 110 is zero, meaning the protrusion 120 and the flat plate 110 are located in the same plane, and the connecting bridge 130 protrudes from the flat plate 110. The insulating plate 100 also includes a partition plate 150, which is disposed within the insulating cavity. The partition plate 150 connects the protrusion 120 and the connecting bridge 130, dividing the insulating cavity into a first sub-insulating cavity and a second sub-insulating cavity. Along the second direction Y, the height of the first horizontal post 213 is greater than the height of the first sub-insulating cavity, and the height of the second horizontal post 214 is greater than the height of the second sub-insulating cavity. The first horizontal post 213 passes through the first sub-insulating cavity, with a portion of the first horizontal post 213 located inside the first sub-insulating cavity and another portion located outside the first sub-insulating cavity. The second horizontal post 214 passes through the second sub-insulating cavity, with a portion of the second horizontal post 214 located inside the second sub-insulating cavity and another portion located outside the second sub-insulating cavity.

[0075] The transformer includes two first windings 220 and two second windings 230. The two first windings 220 are respectively wound on the outside of the two second windings 230. The first part 221 of the two first windings 220 is respectively disposed on the side of the protrusion 120 away from the insulation cavity. The second part 222 of the two first windings 220 is respectively disposed in the partition plate 150 and the connecting bridge 130. The two second windings 230 are respectively disposed in the first sub-insulation cavity and the second sub-insulation cavity, and are wound on the first horizontal column 213 and the second horizontal column 214.

[0076] With the above Figures 1-4 Compared to the embodiment shown, this embodiment can make full use of the structure of the magnetic core 210, which is beneficial to improving the power density of the power module, thereby enabling the power module to meet the demand for higher power.

[0077] In one possible implementation, such as Figures 13-16 As shown, along the third direction Z, the distance between the connecting bridge 130 and the flat plate 110 is zero, meaning the connecting bridge 130 and the flat plate 110 are located in the same plane, and the protrusion 120 protrudes from the flat plate 110. The insulating plate 100 also includes a partition plate 150, which is disposed within the insulating cavity. The partition plate 150 connects the protrusion 120 and the connecting bridge 130, and divides the insulating cavity into a first sub-insulating cavity and a second sub-insulating cavity. Along the second direction Y, the height of the first horizontal post 213 is greater than the height of the first sub-insulating cavity, and the height of the second horizontal post 214 is greater than the height of the second sub-insulating cavity. The first horizontal post 213 passes through the first sub-insulating cavity, with a portion of the first horizontal post 213 located inside the first sub-insulating cavity and another portion located outside the first sub-insulating cavity. The second horizontal post 214 passes through the second sub-insulating cavity, with a portion of the second horizontal post 214 located inside the second sub-insulating cavity and another portion located outside the second sub-insulating cavity.

[0078] The transformer includes two first windings 220 and two second windings 230. The two first windings 220 are respectively wound on the outside of the two second windings 230. The first part 221 of the two first windings 220 is respectively disposed on the side of the protrusion 120 away from the insulation cavity. The second part 222 of the two first windings 220 is respectively disposed in the partition plate 150 and the connecting bridge 130. The two second windings 230 are respectively disposed in the first sub-insulation cavity and the second sub-insulation cavity, and are wound on the first horizontal column 213 and the second horizontal column 214.

[0079] With the above Figures 5-8 Compared to the embodiment shown, this embodiment can make full use of the structure of the magnetic core 210, which is beneficial to improving the power density of the power module, thereby enabling the power module to meet the demand for higher power.

[0080] In traditional power module structures, the size of the air gap in the magnetic core can generally only be adjusted in the direction of the insulation plate thickness, i.e., the third direction Z. However, due to the limitations of the insulation plate and internal space, the air gap cannot be flexibly adjusted, thus restricting the overall design. In this embodiment, at least a portion of the magnetic core 210 is disposed within the insulation cavity, allowing the air gap to be adjusted in three directions: the first direction X, the second direction Y, and the third direction Z. The size of the air gap can be freely adjusted according to the electrical parameter requirements of the transformer, greatly increasing the flexibility of the magnetic core design. It also makes it easier to control the size and tolerance of the air gap and the inductance value of the magnetic core, which is beneficial to improving the efficiency of the transformer in the power module. In addition, the protrusion 120 or connecting bridge 130 provided on the flat plate 110 forms a bent structure for the insulation plate 100, which helps to improve the overall strength of the insulation plate 100. This allows a thinner insulation plate 100 to meet the requirements, which helps to reduce the overall weight of the power module.

[0081] Please continue to refer to Figure 3 , Figure 7 , Figure 11 and Figure 15 In a cross-sectional view of the magnetic core 210 and the insulating plate 100, which is parallel to the second reference plane and passes through the magnetic core 210 and the insulating plate 100, the magnetic core 210 includes a first endpoint 201, a second endpoint 202, a third endpoint 203 and a fourth endpoint 204; that is, the first endpoint 201, the second endpoint 202, the third endpoint 203 and the fourth endpoint 204 are the four vertices of the magnetic core 210 in the plane.

[0082] Along the third direction Z, the first endpoint 201 and the second endpoint 202 are located at the two ends of the magnetic core 210 near the protrusion 120, respectively. The third endpoint 203 and the fourth endpoint 204 are located at the two ends of the magnetic core 210 away from the protrusion 120, respectively. That is, the third endpoint 203 is located on the side of the first endpoint 201 away from the protrusion 120, and the fourth endpoint 204 is located on the side of the second endpoint 202 away from the protrusion 120. It should be noted that in Figure 7 In the illustrated embodiment, since part of the magnetic core 210 is located within the insulating cavity in the plane formed by the first direction X and the third direction Z, the first endpoint 201 and the second endpoint 202 are the two endpoints of the magnetic core 210 located within the insulating cavity, while the third endpoint 203 and the fourth endpoint 204 are the two endpoints of the magnetic core 210 located outside the insulating cavity. Figure 15 In the embodiment shown, since the magnetic core 210 is located in the insulating cavity within the plane formed by the first direction X and the third direction Z, the first endpoint 201 and the second endpoint 202 are the two endpoints of the magnetic core 210 away from the plate portion 110, while the third endpoint 203 and the fourth endpoint 204 are the two endpoints of the magnetic core 210 close to the plate portion 110.

[0083] Along the first direction X, the first shielding layer 500 includes a first shielding end 501 and a second shielding end 502. The first shielding end 501 is close to the first endpoint 201, which can also be understood as the first shielding end 501 being located on the side of the first endpoint 201 away from the second endpoint 202. The second shielding end 502 is close to the second endpoint 202, which can also be understood as the second shielding end 502 being located on the side of the second endpoint 202 away from the first endpoint 201. In other words, the length of the first shielding layer 500 in the first direction X is greater than the length of the magnetic core 210 in the first direction X. Therefore, the first shielding layer 500 can eliminate the air field strength around the magnetic core 210 in the first direction X, extend the insulation life, and improve the reliability of the product.

[0084] Please continue to refer to Figure 4 , Figure 8 , Figure 12 and Figure 16 In a cross-sectional view of the magnetic core 210 and the insulating plate 100, parallel to the third reference plane and passing through the magnetic core 210 and the insulating plate 100, the magnetic core 210 includes a fifth endpoint 205, a sixth endpoint 206, a seventh endpoint 207, and an eighth endpoint 208; that is, the fifth endpoint 205, the sixth endpoint 206, the seventh endpoint 207, and the eighth endpoint 208 are the four vertices of the magnetic core 210 in this plane. Along the third direction Z, the fifth endpoint 205 and the sixth endpoint 206 are located at the two ends of the magnetic core 210 near the protrusion 120, and the seventh endpoint 207 and the eighth endpoint 208 are located at the two ends of the magnetic core 210 away from the protrusion 120, that is, the seventh endpoint 207 is located on the side of the fifth endpoint 205 away from the protrusion 120, and the eighth endpoint 208 is located on the side of the sixth endpoint 206 away from the protrusion 120.

[0085] Along the second direction Y, the first shielding layer 500 includes a third shielding end 503 and a fourth shielding end 504. The third shielding end 503 is close to the fifth endpoint 205, which can also be understood as the third shielding end 503 being located on the side of the fifth endpoint 205 away from the sixth endpoint 206. The fourth shielding end 504 is close to the sixth endpoint 206, which can also be understood as the fourth shielding end 504 being located on the side of the sixth endpoint 206 away from the fifth endpoint 205. In other words, the length of the first shielding layer 500 in the second direction Y is greater than the length of the magnetic core 210 in the second direction Y. Therefore, the first shielding layer 500 can eliminate the air field strength around the magnetic core 210 in the second direction Y, extend the insulation life, and improve the reliability of the product.

[0086] Please continue to refer to Figure 4 , Figure 8 , Figure 12 and Figure 16In some possible implementations, along the second direction Y, the distance between the third shielding end 503 and the fifth end point 205 is H3, and along the third direction Z, the distance between the seventh end point 207 and the protrusion 120 is D3, where H3 / D3 satisfies a value greater than or equal to a third threshold and less than or equal to a fourth threshold. For example, in this embodiment, the third threshold can be 1.5, and the fourth threshold can be 3, i.e., 1.5 ≤ H3 / D3 ≤ 3. When H3 / D3 is less than the third threshold, the shielding effect of the first shielding layer 500 is poor; while when H3 / D3 is greater than the fourth threshold, the shielding effect of the first shielding layer 500 does not change significantly. Therefore, when the first shielding layer 500 is set within the above parameter range, it can be ensured that the first shielding layer 500 has a good shielding effect without significantly affecting the power density of the power module.

[0087] Along the second direction Y, the distance between the fourth shielding end 504 and the sixth end point 206 is H4. Along the third direction Z, the distance between the eighth end point 208 and the protrusion 120 is D4. H4 / D4 satisfies a condition greater than or equal to a third threshold and less than or equal to a fourth threshold. The third threshold can be 1.5, and the fourth threshold can be 3, i.e., 1.5 ≤ H4 / D4 ≤ 3. When H4 / D4 is less than the third threshold, the shielding effect of the first shielding layer 500 is poor; while when H4 / D4 is greater than the fourth threshold, the shielding effect of the first shielding layer 500 does not change significantly. Therefore, when the first shielding layer 500 is set within the above parameter range, it can ensure that the first shielding layer 500 has a good shielding effect without significantly affecting the power density of the power module.

[0088] In this embodiment, the endpoints of the first shielding layer 500 in the second direction Y and the corresponding endpoints of the magnetic core in the second direction Y are set within the above-mentioned ratio range, which can both meet the shielding requirements and reduce the size of the first shielding layer 500 in the second direction Y.

[0089] In some implementations, since the transformer connects the circuit board and electronic devices, and the circuit board and electronic devices are relatively large in the first direction X, the first shielding layer 500 needs to be adjusted according to the size of these devices. In the first direction X, the size of the first shielding layer 500 needs to be larger than the size of the circuit board and electronic devices.

[0090] Similarly, in other implementations, please continue to refer to... Figure 3 , Figure 7 , Figure 11 and Figure 15Along the first direction X, the distance between the first shielding end 501 and the first endpoint 201 is H1, and along the third direction Z, the distance between the third endpoint 203 and the protrusion 120 is D1. H1 / D1 satisfies a first threshold greater than or equal to a first threshold and a second threshold less than or equal to a second threshold. The first threshold can be 1.5, and the second threshold can be 3, i.e., 1.5 ≤ H1 / D1 ≤ 3. When H1 / D1 is less than the first threshold, the shielding effect of the first shielding layer 500 is poor; while when H1 / D1 is greater than the second threshold, the shielding effect of the first shielding layer 500 does not change significantly. Therefore, when the first shielding layer 500 is set within the above parameter range, it can ensure that the first shielding layer 500 has a good shielding effect without significantly affecting the power density of the power module.

[0091] Along the first direction X, the distance between the second shielding end 502 and the second endpoint 202 is H2. Along the third direction Z, the distance between the fourth endpoint 204 and the protrusion 120 is D2. H2 / D2 satisfies a first threshold value greater than or equal to a first threshold value and a second threshold value less than or equal to a second threshold value. The first threshold value can be 1.5, and the second threshold value can be 3, i.e., 1.5 ≤ H2 / D2 ≤ 3. When H2 / D2 is less than the first threshold value, the shielding effect of the first shielding layer 500 is poor; while when H2 / D2 is greater than the second threshold value, the shielding effect of the first shielding layer 500 does not change significantly. Therefore, when the first shielding layer 500 is set within the above parameter range, it can ensure that the first shielding layer 500 has a good shielding effect without significantly affecting the power density of the power module.

[0092] In this embodiment, the endpoints of the first shielding layer 500 in the first direction X and the corresponding endpoints of the magnetic core 210 in the first direction X are set within the aforementioned proportional range. This satisfies the shielding requirements while reducing the size of the first shielding layer 500 in the first direction X. If the transformer connects circuit boards and electronic devices in the second direction Y, and the circuit boards and electronic devices are large, the first shielding layer 500 needs to be adjusted according to the size of these devices. In the second direction Y, the size of the first shielding layer 500 needs to be larger than the size of the circuit boards and electronic devices.

[0093] In some other possible implementations, the endpoints of the first shielding layer 500 in the first direction X and the corresponding endpoints of the magnetic core 210 in the first direction X, as well as the endpoints of the first shielding layer 500 in the second direction Y and the corresponding endpoints of the magnetic core in the second direction Y, may all need to meet the above-mentioned ratio range. In this case, there are no external devices around the transformer, or there is no need to shield external devices, or the size of the external electronic devices is small. The first shielding layer 500 can meet the shielding requirements and reduce the size of the first shielding layer 500 within the above-mentioned ratio range.

[0094] Please continue to refer to Figure 1 , Figure 5 , Figure 9 and Figure 13 In this embodiment, the projection of the first shielding layer 500 is located within the projection range of the insulating plate 100 in a plane parallel to the first reference plane, meaning that the first shielding layer 500 will not exceed the range of the insulating plate 100.

[0095] Furthermore, in this embodiment, the first shielding layer 500 is disposed on the side of the flat plate portion 110 along the third direction Z, on the surface of the connecting bridge 130, and on the side of the protrusion portion 120 facing the magnetic core 210.

[0096] Specifically, such as Figures 1-4 As shown, the first shielding layer 500 is disposed on the side of the flat plate portion 110 facing the magnetic core 210 along the third direction Z, the side of the protrusion 120 facing the magnetic core 210, and the surface of the connecting bridge 130. The connecting bridge 130 has a through hole (i.e., the through hole passes through the interior of the connecting bridge 130), and the second part 222 of the first winding 220 is disposed within the through hole of the connecting bridge 130. The first shielding layer 500 is disposed on the inner surface of the through hole and the outer surface of the connecting bridge 130. The first shielding layer 500 disposed on the connecting bridge 130 provides electromagnetic shielding for the second part 222 of the first winding 220.

[0097] like Figures 5-8 As shown, the first shielding layer 500 is disposed on the side of the flat plate portion 110 away from the protrusion 120 along the third direction Z, the side of the protrusion 120 facing the magnetic core 210, and the surface of the connecting bridge 130. The connecting bridge 130 includes a through hole, and the second part 222 of the first winding 220 is disposed in the through hole of the connecting bridge 130. The first shielding layer 500 is disposed on the inner surface of the through hole and the inner and outer surfaces of the connecting bridge 130. The first shielding layer 500 disposed on the connecting bridge 130 provides electromagnetic shielding for the second part 222 of the first winding 220. If the external electronic device is small, or if shielding of the external electronic device is not required along the first direction X, the first shielding layer 500 may not be disposed on the side of the flat plate portion 110 away from the protrusion 120 along the third direction Z.

[0098] like Figures 9-12 As shown, a first shielding layer 500 is disposed on the side of the flat plate portion 110 facing the magnetic core 210 along the third direction Z, the side of the protrusion 120 facing the magnetic core 210, the surface of the connecting bridge 130, and the surface of the partition plate 150. The connecting bridge 130 includes a through hole, and the second part 222 of the first winding 220 is disposed within the through hole of the connecting bridge 130. The first shielding layer 500 is disposed on the inner surface of the through hole, the outer surface of the connecting bridge 130, and the surface of the partition plate 150. The first shielding layer 500 disposed on the connecting bridge 130 and the partition plate 150 provides electromagnetic shielding for the second part 222 of the first winding 220.

[0099] like Figures 13-16As shown, the first shielding layer 500 is disposed on the side of the flat plate 110 away from the protrusion 120 along the third direction Z, the side of the protrusion 120 facing the magnetic core 210, the surface of the connecting bridge 130, and the surface of the partition plate 150. The connecting bridge 130 includes a through hole, and the second part 222 of the first winding 220 is disposed in the through hole of the connecting bridge 130. The first shielding layer 500 is disposed on the inner surface of the through hole, the inner and outer surfaces of the connecting bridge 130, and the surface of the partition plate 150. The first shielding layer 500 disposed on the connecting bridge 130 and the partition plate 150 provides electromagnetic shielding for the second part 222 of the first winding 220. If the external electronic device is small, or if shielding of the external electronic device is not required along the first direction X, the first shielding layer 500 may not be disposed on the side of the flat plate 110 away from the protrusion 120 along the third direction Z. In some possible implementations, the insulating plate 100 of this embodiment is further provided with a second shielding layer (not shown in the figure) on the side facing the magnetic core 210. The second shielding layer is connected to the first shielding layer 500 and surrounds the outer periphery of the first shielding layer 500. The resistivity of the second shielding layer is greater than the resistivity of the first shielding layer 500.

[0100] For example, the second shielding layer in this embodiment is also a semiconductive layer, and the material of the second shielding layer includes graphene or carbon black. The first shielding layer 500 and the second shielding layer can be integrally formed. The conductivity (resistivity and conductivity are reciprocals of each other) of both the first shielding layer 500 and the second shielding layer can be uniform or non-uniform. Furthermore, the minimum conductivity of the first shielding layer 500 is greater than the maximum conductivity of the second shielding layer.

[0101] Optionally, the first shielding layer 500 and the second shielding layer can be made of different materials, and the conductivity of the material used in the first shielding layer 500 is greater than that of the material used in the second shielding layer. Alternatively, the first shielding layer 500 and the second shielding layer can be made of the same material, but the concentration of conductive material in the first shielding layer 500 is greater than the concentration of conductive material in the second shielding layer; or, the material thickness of the first shielding layer 500 is greater than the material thickness of the second shielding layer.

[0102] In this embodiment, by providing a second shielding layer on the outer periphery of the first shielding layer 500, the electric field strength at the edge of the first shielding layer 500 can be reduced, the occurrence of discharge can be reduced, and the product life can be increased.

[0103] Please continue to refer to Figures 1-16 In this embodiment, the insulating plate 100 facing the first portion 221 is further provided with a third shielding layer 600. Exemplarily, the third shielding layer 600 is a semi-conductive layer, and the material of the third shielding layer 600 includes graphene or carbon black. In a plane parallel to the first reference plane, the projection of the first portion 221 lies within the projection range of the third shielding layer 600.

[0104] With the above structure, this embodiment can adjust the air field strength around the first part 221 through the third shielding layer 600, thereby extending the insulation life and improving the reliability of the product.

[0105] Furthermore, the insulating plate 100 is provided with a fourth shielding layer (not shown in the figure) on the side facing the first part 221. The fourth shielding layer is connected to the third shielding layer 600 and surrounds the outer periphery of the third shielding layer 600. The resistivity of the fourth shielding layer is greater than that of the third shielding layer 600.

[0106] For example, the fourth shielding layer in this embodiment is also a semiconductive layer, and the material of the fourth shielding layer includes graphene or carbon black. The third shielding layer 600 and the fourth shielding layer can be integrally formed. The conductivity of both the third shielding layer 600 and the fourth shielding layer can be uniform or non-uniform. Furthermore, the minimum conductivity of the third shielding layer 600 is greater than the maximum conductivity of the fourth shielding layer.

[0107] Optionally, the third shielding layer 600 and the fourth shielding layer can be made of different materials, and the conductivity of the material used in the third shielding layer 600 is greater than that of the material used in the fourth shielding layer. Alternatively, the third shielding layer 600 and the fourth shielding layer can be made of the same material, but the concentration of conductive material in the third shielding layer 600 is greater than that in the fourth shielding layer; or, the material thickness of the third shielding layer 600 is greater than that of the fourth shielding layer.

[0108] This embodiment reduces the electric field strength at the edge of the third shielding layer 600 by providing a fourth shielding layer on the outer periphery of the third shielding layer 600, thereby reducing discharge and increasing product lifespan.

[0109] Optionally, the resistivity of the materials selected for the first shielding layer 500 and the third shielding layer 600 can be the same, or the resistivity of the materials selected can be different according to actual needs.

[0110] Optionally, the resistivity of the materials selected for the second and fourth shielding layers can be the same, or the resistivity of the materials selected can be different depending on actual needs.

[0111] Optionally, the magnetic core 210 can be a U-shaped magnetic core, an E-shaped magnetic core, or other shapes of magnetic core. In a plane parallel to the second reference plane, the magnetic core 210 includes a vertex near the protrusion 120 and a vertex away from the protrusion 120; in a plane parallel to the third reference plane, the magnetic core 210 includes a vertex near the protrusion 120 and a vertex away from the protrusion 120.

[0112] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0113] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0114] It should be noted that in the description of this application, the terms "first" and "second" are used only for convenience in describing different components and should not be construed as indicating or implying a sequential relationship, relative importance, or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of those features.

[0115] The embodiments or implementation methods in this application are described in a progressive manner. Each embodiment focuses on the differences from other embodiments, and the same or similar parts between the embodiments can be referred to each other.

[0116] In the description of this application, the terms "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with an embodiment or example that are included in at least one embodiment or example of this application. In this application, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0117] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A power module, characterized by The transformer comprises a magnetic core and a first winding wound on the magnetic core, the first winding comprises a first part and a second part electrically connected, the first part is located on a side of the insulation plate away from the magnetic core, and the second part is arranged in the insulation plate. A first shielding layer is arranged on at least one side of the insulation plate facing the magnetic core. In a first reference plane parallel to the flat plate part, a projection of the magnetic core is located in a projection range of the first shielding layer. The insulation plate further comprises a protruding part and a communication bridge, the flat plate part is parallel to the first reference plane composed of a first direction and a second direction, the protruding part and / or the communication bridge protrude from the flat plate part along a third direction, thereby forming an insulation cavity; At least part of the magnetic core is arranged in the insulation cavity, the first part is located on a side of the protruding part away from the insulation cavity, the second part is located in the communication bridge, and the transformer further comprises a second winding directly wound on the magnetic core.

2. The power module of claim 1, wherein, The magnetic core comprises a first vertical column and a second vertical column arranged oppositely and a first horizontal column and a second horizontal column arranged oppositely, and the first vertical column, the first horizontal column, the second vertical column and the second horizontal column are sequentially connected in order. The first direction, the second direction and the third direction are perpendicular to each other. In a second reference plane parallel to the first direction and the third direction, the magnetic core comprises a first end point, a second end point, a third end point and a fourth end point. Along the third direction, the first end point and the second end point are respectively located at two ends of the magnetic core close to the protruding part, and the third end point and the fourth end point are respectively located at two ends of the magnetic core away from the protruding part.

3. The power module of claim 2, wherein, Along the first direction, the first shielding layer comprises a first shielding end and a second shielding end, the first shielding end is close to the first end point, and the second shielding end is close to the second end point. In a third reference plane parallel to the second direction and the third direction, the magnetic core comprises a fifth end point, a sixth end point, a seventh end point and an eighth end point; along the third direction, the fifth end point and the sixth end point are respectively located at two ends of the magnetic core close to the protruding part, and the seventh end point and the eighth end point are respectively located at two ends of the magnetic core away from the protruding part; Along the second direction, the first shielding layer comprises a third shielding end and a fourth shielding end, the third shielding end is close to the fifth end point, and the fourth shielding end is close to the sixth end point.

4. The power module of claim 2, wherein, Along the first direction, the distance between the first shielding end and the first end point is H1, and along the third direction, the distance between the third end point and the protruding part is D1. Along the first direction, the distance between the second shielding end and the second end point is H2, and along the third direction, the distance between the fourth end point and the protruding part is D2, wherein H1 / D1 and H2 / D2 satisfy that they are greater than or equal to a first threshold value and less than or equal to a second threshold value.

5. The power module of claim 3, wherein, The first threshold value is 1.5, and the second threshold value is 3. ​ 6. The power module of claim 5, wherein, ​ 7. The power module of claim 4, wherein, In the second direction, the distance between the third shielding end and the fifth end point is H3, and in the third direction, the distance between the seventh end point and the protruding portion is D3; In the second direction, the distance between the fourth shielding end and the sixth end point is H4, and in the third direction, the distance between the eighth end point and the protruding portion is D4, wherein H3 / D3 and H4 / D4 satisfy a condition of being greater than or equal to a third threshold value and less than or equal to a fourth threshold value.

8. The power module of claim 7, wherein, The third threshold value is 1.5, and the fourth threshold value is 3.

9. The power module of claim 2, wherein, In a plane parallel to the first reference plane, a projection of the first shielding layer is located within a projection range of the insulating plate.

10. The power module of claim 2, wherein, The first shielding layer is arranged on one side of the flat portion along the third direction, a surface of the communication bridge, and one side of the protruding portion facing the magnetic core.

11. The power module of claim 1, wherein, A second shielding layer is further included, which is arranged on one side of the insulating plate facing the magnetic core, connected to the first shielding layer, and surrounds an outer periphery of the first shielding layer, and has a resistivity greater than that of the first shielding layer.

12. The power module of any one of claims 1-11, wherein, A third shielding layer is further included, which is arranged on one side of the insulating plate facing the first portion, and in a plane parallel to the first reference plane, a projection of the first portion is located within a projection range of the third shielding layer.

13. The power module of claim 12, wherein, A fourth shielding layer is further included, which is arranged on one side of the insulating plate facing the first portion, connected to the third shielding layer, and surrounds an outer periphery of the third shielding layer, and has a resistivity greater than that of the third shielding layer.

14. The power module of claim 2, wherein, In the third direction, the distance between the communication bridge and the flat portion is zero, the protruding portion protrudes from the flat portion, the first vertical column is located within the insulating cavity, the second vertical column is located outside the insulating cavity, and the second winding is wound on the first vertical column.

15. The power module of claim 2, wherein, In the third direction, the distance between the protruding portion and the flat portion is zero, the communication bridge protrudes from the flat portion, the first vertical column is located within the insulating cavity, the second vertical column is located outside the insulating cavity, and the second winding is wound on the first vertical column.

16. The power module of claim 2, wherein, The insulating plate further includes a partition plate arranged in the insulating cavity, the partition plate connects the protruding portion and the communication bridge, and the partition plate divides the insulating cavity into a first sub-insulating cavity and a second sub-insulating cavity, the first vertical column is located in the first sub-insulating cavity, and the second vertical column is located in the second sub-insulating cavity.

17. The power module of claim 16, wherein, The transformer includes two first windings and two second windings, the two first windings are respectively wound on the outer sides of the two second windings, the first portions of the two first windings are respectively arranged on one side of the protruding portion away from the insulating cavity, the second portions of the two first windings are respectively arranged in the partition plate and the communication bridge, and the two second windings are respectively wound on the first vertical column and the second vertical column.

18. The power module of claim 16, wherein, In the third direction, the distance between the protruding portion and the flat portion is zero, and the communication bridge protrudes from the flat portion.

19. The power module of claim 16, wherein, In the third direction, the distance between the communication bridge and the flat plate portion is zero, and the convex portion protrudes from the flat plate portion.

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