LLC magnetic integrated transformer

Abstract

The utility model discloses an LLC magnetic integrated transformer, and aims to improve the integration level, the performance and the reliability. The transformer comprises a winding support, an upper magnetic core and a lower magnetic core which are symmetrically arranged, and a placing magnetic core fixed in a through hole of the winding support. The through hole is divided into a first containing groove and a second containing groove, the magnetic core is placed in the first containing groove, and the side edge protruding columns of the upper magnetic core and the lower magnetic core are arranged in the second containing groove. And a first air gap and a second air gap are respectively arranged between the magnetic core and the side edge convex columns and between the side edge convex columns and are used for adjusting magnetic resistance and optimizing performance.

Description

Technical Field

[0001] This utility model relates to the field of transformer technology, specifically to an LLC magnetically integrated transformer. Background Technology

[0002] In modern electronic devices, LLC resonant converters are widely used due to their high efficiency, high power density, and good load adaptability. Among these, the transformer, as a key component of the LLC resonant converter, plays a crucial role in the efficiency and stability of the entire circuit. Traditional LLC transformers typically consist of a winding support, an upper magnetic core, and a lower magnetic core, with magnetic flux transmitted between the cores through an air gap. However, this design has a significant limitation: the leakage inductance of the transformer is difficult to control and adjust precisely.

[0003] Leakage inductance is a crucial parameter in transformer design, directly impacting efficiency, power factor, and electromagnetic compatibility (EMC). In traditional designs, leakage inductance is primarily determined by the core structure and winding layout; once the core and windings are fixed, the magnitude of the leakage inductance is difficult to alter. This makes it challenging for engineers to optimize the leakage inductance for different operating conditions and requirements, thus limiting further improvements in transformer performance. For instance, in high-power-density applications, a small leakage inductance may lead to reduced transformer efficiency, while in electromagnetically sensitive environments, a large leakage inductance may cause EMC problems. Therefore, effectively adjusting and optimizing transformer leakage inductance has become a pressing issue in transformer design. Utility Model Content

[0004] To address the problem of difficulty in adjusting the leakage inductance of existing LLC magnetically integrated transformers, this invention provides an LLC magnetically integrated transformer. The specific technical solution of this invention is as follows:

[0005] An LLC magnetically integrated transformer includes: a winding bracket, an upper magnetic core, a lower magnetic core, and a placement magnetic core. The upper and lower magnetic cores are symmetrically arranged on the upper and lower sides of the winding bracket. One end of the winding bracket is provided with a through hole, which includes a first receiving groove and a second receiving groove. The first receiving groove is located on the outermost side. The placement magnetic core is fixedly disposed in the first receiving groove. A side protrusion is provided at the same end of both the upper and lower magnetic cores. The side protrusion is disposed in the second receiving groove. A first air gap is provided between the placement magnetic core and the side protrusion, and a second air gap is provided between the side protrusions of the upper and lower magnetic cores.

[0006] Furthermore, the winding bracket has protrusions on both sides, and pins are provided on the protrusions. A guide groove is provided on the bottom surface of one of the protrusions of the winding bracket, and conductive adhesive is provided in the guide groove. The conductive adhesive connects the pins located in the guide groove to the lower magnetic core.

[0007] Furthermore, a wire feeding groove is provided between the protrusions at one end of the winding bracket.

[0008] Furthermore, a winding groove is provided at the middle position of the winding bracket.

[0009] Furthermore, the top and bottom of the winding bracket opposite to the through hole are provided with V-shaped protrusions, and the upper and lower magnetic cores are provided with V-shaped grooves that cooperate with the V-shaped protrusions.

[0010] Furthermore, the magnetic core is inserted into the first receiving groove from top to bottom, and limiting protrusions are provided on both sides of the upper end of the magnetic core, and the limiting protrusions are located on the top of the winding skeleton.

[0011] Furthermore, the width of the magnetic core placement area is greater than the width of the side protrusions, and both widths are measured along the left and right sides of the winding skeleton.

[0012] Furthermore, the upper and lower magnetic cores have the same structure. The upper magnetic core has a central protrusion in the middle and supporting protrusions on both sides. The central protrusion passes through the winding bracket and abuts against it. The supporting protrusions abut against each other on both sides of the winding bracket.

[0013] Furthermore, the pins are gull pins, L pins, or through pins.

[0014] Compared with existing technologies, the beneficial effects of this utility model are as follows: The LLC magnetically integrated transformer described in this application is provided with a leakage inductance adjustment structure for placing the magnetic core and side protrusions. The interaction between the magnetic core and the side protrusions can significantly increase the leakage inductance of the transformer, which can improve the efficiency, power factor and electromagnetic compatibility of the LLC resonant converter, thereby improving the performance and reliability of the entire power supply system. By adjusting the size of the first air gap between the magnetic core and the side protrusions and the second air gap between the side protrusions, the leakage inductance of the transformer can be precisely adjusted, thereby meeting the leakage inductance requirements of different application scenarios and improving the adaptability and flexibility of the transformer. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of an LLC magnetically integrated transformer in one embodiment of the present invention;

[0016] Figure 2 This is an exploded view of an LLC magnetically integrated transformer in one embodiment of the present invention. Figure 1 ;

[0017] Figure 3 This is a side view of an LLC magnetically integrated transformer in one embodiment of the present invention;

[0018] Figure 4 This is a cross-sectional schematic diagram of an LLC magnetically integrated transformer in one embodiment of the present invention;

[0019] Figure 5 This is a top view of a winding bracket in one embodiment of the present invention;

[0020] Figure 6 This is an exploded view of an LLC magnetically integrated transformer in one embodiment of the present invention. Figure 2 ;

[0021] Figure 7 This is a bottom view structural diagram of an LLC magnetically integrated transformer in one embodiment of the present invention. Detailed Implementation

[0022] The embodiments of this utility model are described in detail below. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout.

[0023] In the description of this utility model, it should be noted that the directional terms such as "center", "lateral", "longitudinal", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", and "counterclockwise" are based on the orientation or positional relationship shown in the accompanying drawings. They 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 be constructed and operated in a specific orientation. They should not be construed as limiting the specific protection scope of this utility model.

[0024] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features. Thus, the use of "first" and "second" to define a feature may explicitly or implicitly include one or more of that feature, and in this description of the utility model, "at least" means one or more, unless otherwise explicitly specified.

[0025] In this utility model, unless otherwise explicitly specified and limited, the terms "assembly," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can also refer to a mechanical connection; they can refer to a direct connection or a connection through an intermediate medium; or they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0026] In utility models, unless otherwise specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "below," and "over" the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Above," "below," and "below" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0027] The following description, in conjunction with the accompanying drawings, further illustrates specific embodiments of the present invention, making the technical solution and beneficial effects of the present invention clearer and more explicit. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, but should not be construed as limiting the present invention.

[0028] like Figures 1 to 5 As shown, an LLC magnetically integrated transformer is proposed, aiming to improve the integration, performance, and reliability of transformers while optimizing their structural design. The specific technical solution is as follows:

[0029] The LLC magnetically integrated transformer includes a winding bracket 1, an upper magnetic core 2, a lower magnetic core 3, and a placement core 4. The upper magnetic core 2 and lower magnetic core 3 are symmetrically arranged on the upper and lower sides of the winding bracket 1. This symmetrical design ensures the magnetic circuit balance of the transformer and improves conversion efficiency. One end of the winding bracket 1 has a through hole 5, which includes a first receiving groove 6 and a second receiving groove 7. The first receiving groove 6 is located on the outermost side, and the placement core 4 is fixedly disposed in the first receiving groove 6. A side protrusion 8 is provided at the same end of both the upper magnetic core 2 and the lower magnetic core 3, and the side protrusion 8 is disposed in the second receiving groove 7. A first air gap 9 is provided between the placement core 4 and the side protrusion 8, and a second air gap 10 is provided between the side protrusion 8 of the upper magnetic core 2 and the lower magnetic core 3. These air gaps can adjust the magnetic reluctance of the magnetic circuit and optimize the transformer performance. The spacing of the first air gap 9 is greater than 0.01 mm. The spacing of the second air gap 10 is greater than 0.01 mm.

[0030] In one embodiment, the winding bracket 1 has protrusions 11 on both sides at both ends, and pins are provided on the protrusions 11. A conductive adhesive groove 22 is provided on the bottom surface of one of the protrusions 11 of the winding bracket 1. Conductive adhesive is provided in the conductive adhesive groove 22, which electrically connects the pins located in the conductive adhesive groove 22 to the lower magnetic core. The pins located in the conductive adhesive groove 22 are grounding pins. Existing products require additional grounding leads, which not only wastes winding time and production efficiency but also easily leads to lower magnetic core conductivity. By adding a conductive adhesive groove 22 to the bottom of the winding bracket 1, and injecting conductive adhesive into the conductive adhesive groove 22 after soldering assembly, allowing the pins to directly contact the lower magnetic core, the conductivity of the LLC integrated magnetic transformer can be increased by 50%.

[0031] In one embodiment, the pins are gull-shaped pins 14, L-shaped pins 13, or through-hole pins 12. Gull-shaped pins 14 or L-shaped pins 13 facilitate the connection of the transformer to circuits with different functions. In electronic components, "gull-shaped pin" refers to a special pin shape. For example, electronic components such as gull-shaped network transformers or gull-shaped surface-mount rectifier bridges have pins shaped like seagull feet, with a unique arrangement that facilitates soldering and mounting. This design enhances solderability and improves component stability and reliability. L-shaped pins: These pins are typically used for surface-mount components (SMD). The pins extend from the component body and are bent into an L-shape for easy soldering onto the PCB board. This design saves space and improves component stability. Through-hole pins 12 are rod-shaped and located at the bottom of the protrusion 11.

[0032] In one embodiment, a wire feeding groove 15 is provided between the protrusions 11 at one end of the winding bracket 1. This design facilitates the connection between the coil wire end and the pin.

[0033] In one embodiment, a winding groove 16 is provided at the middle position of the winding bracket 1. The winding groove 16 is used to wind the coil of the transformer.

[0034] In one embodiment, the top and bottom of the winding bracket 1 opposite to the through hole 5 are provided with V-shaped protrusions 17, and the upper magnetic core 2 and lower magnetic core 3 are provided with V-shaped grooves 18 that cooperate with the V-shaped protrusions 17. This design can further enhance the fixing effect between the magnetic core and the winding bracket 1 and improve the structural stability of the transformer.

[0035] In one embodiment, the magnetic core 4 is inserted into the first receiving groove 6 from top to bottom. Limiting protrusions 19 are provided on both sides of the upper end of the magnetic core 4, and these protrusions 19 are located on the top of the winding bracket 1. This design facilitates the installation of the magnetic core 4 into the winding bracket 1.

[0036] In one embodiment, the width of the magnetic core 4 is greater than the width of the side protrusion 8, and both widths are measured along the left and right sides of the winding bracket 1. Placing the magnetic core 4 over the side protrusion 8 optimizes the magnetic flux distribution in the magnetic circuit and improves the transformer's conversion efficiency.

[0037] In one embodiment, the upper magnetic core 2 and the lower magnetic core 3 have the same structure. The upper magnetic core 2 has a central protrusion 20 in the middle and supporting protrusions 21 on both sides. The central protrusion 20 passes through the winding bracket 1 and abuts against it. The supporting protrusions 21 abut against each other on both sides of the winding bracket 1.

[0038] like Figure 6 and Figure 7 As shown, the upper magnetic core 2 and the lower magnetic core 3 can set one side of the V-groove 18 as a plane, so that the V-shaped protrusion 17 on the winding bracket 1 will also become a protrusion that fits the plane.

[0039] The LLC magnetically integrated transformer described in this application is provided with a leakage inductance adjustment structure for placing the magnetic core 4 and the side protrusions 8. The interaction between the magnetic core 4 and the side protrusions 8 can significantly increase the leakage inductance of the transformer, which can improve the efficiency, power factor and electromagnetic compatibility of the LLC resonant converter, thereby improving the performance and reliability of the entire power supply system. By adjusting the size of the first air gap 9 between the magnetic core 4 and the side protrusions 8 and the second air gap 10 between the side protrusions 8, the leakage inductance of the transformer can be precisely adjusted, thereby meeting the leakage inductance requirements of different application scenarios and improving the adaptability and flexibility of the transformer.

[0040] In the description of this specification, the terms "in one embodiment," "preferred," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this utility model. The illustrative expressions of the above terms in this specification do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described can be combined in any suitable manner in one or more embodiments or examples. The connection methods linked in the description of this specification have significant effects and practical utility.

[0041] Based on the above description of the structure and principle, those skilled in the art should understand that this utility model is not limited to the specific embodiments described above. Improvements and substitutions based on this utility model using techniques known in the art all fall within the protection scope of this utility model and should be defined by the claims.

Claims

1. An LLC magnetically integrated transformer, characterized in that, include: The winding bracket comprises an upper magnetic core, a lower magnetic core, and a placement magnetic core. The upper and lower magnetic cores are symmetrically arranged on the upper and lower sides of the winding bracket. One end of the winding bracket is provided with a through hole, which includes a first receiving groove and a second receiving groove. The first receiving groove is located on the outermost side. The placement magnetic core is fixedly disposed in the first receiving groove. A side protrusion is provided at the same end of both the upper and lower magnetic cores. The side protrusion is disposed in the second receiving groove. A first air gap is provided between the placement magnetic core and the side protrusion, and a second air gap is provided between the side protrusions of the upper and lower magnetic cores.

2. The LLC magnetically integrated transformer according to claim 1, characterized in that, The winding bracket has protrusions on both sides at both ends, and pins are provided on the protrusions. A guide groove is provided on the bottom surface of one of the protrusions of the winding bracket, and conductive adhesive is provided in the guide groove. The conductive adhesive connects the pin located in the guide groove to the lower magnetic core.

3. The LLC magnetically integrated transformer according to claim 2, characterized in that, A wire feeding groove is provided between the protrusions at one end of the winding bracket.

4. The LLC magnetically integrated transformer according to claim 1, characterized in that, A winding groove is provided at the middle position of the winding bracket.

5. The LLC magnetically integrated transformer according to claim 1, characterized in that, The winding bracket has V-shaped protrusions at the top and bottom of the end opposite to the through hole, and the upper and lower magnetic cores have V-shaped grooves that cooperate with the V-shaped protrusions.

6. The LLC magnetically integrated transformer according to claim 1, characterized in that, The magnetic core is inserted into the first receiving groove from top to bottom. Limiting protrusions are provided on both sides of the upper end of the magnetic core, and the limiting protrusions are located on the top of the winding skeleton.

7. The LLC magnetically integrated transformer according to claim 1, characterized in that, The width of the magnetic core is greater than the width of the side protrusion, and both widths are measured along the left and right sides of the winding skeleton.

8. The LLC magnetically integrated transformer according to claim 1, characterized in that, The upper and lower magnetic cores have the same structure. The upper magnetic core has a central protrusion in the middle and supporting protrusions on both sides. The central protrusion passes through the winding bracket and abuts against it. The supporting protrusions abut against each other on both sides of the winding bracket.

9. The LLC magnetically integrated transformer according to claim 2, characterized in that, The pins are either gull pins, L pins, or straight pins.

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