High-power U-shaped output pin LLC planar transformer without additional resonant inductor
By using a U-shaped output pin LLC planar transformer design that eliminates the need for an external resonant inductor, the problem of increased power supply size and cost in existing technologies is solved, achieving transformer miniaturization and cost reduction, while improving product consistency and performance.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- ZIXING HUIHUA ELECTRONICS CO LTD
- Filing Date
- 2025-04-29
- Publication Date
- 2026-05-05
AI Technical Summary
Existing high-power power transformers require an external resonant inductor to meet leakage inductance requirements, which increases the size and cost of the power supply, especially when the size of the circuit board is limited.
The design of a high-power U-shaped output-pin LLC planar transformer that does not require an external resonant inductor is achieved by assembling the main transformer coil, PCB, output components and magnetic core using a glue-fixing method, and integrating the resonant inductor using copper-clad aluminum material and a multi-layer through-hole structure.
The transformer size was reduced, costs were lowered, product consistency and performance were improved, and the resonant inductance could be adjusted to meet performance and safety requirements as needed by the circuit.
Smart Images
Figure CN224203937U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the technical field of transformers, specifically a high-power U-shaped output pin LLC planar transformer that does not require an external resonant inductor. Background Technology
[0002] Currently, most high-power power transformers on the market use LLC topology. Since LLC topology requires the leakage inductance of the transformer to generate resonance in order to work, there are strict requirements on the range of leakage inductance. At this time, it is difficult to meet the requirements by relying solely on the leakage inductance generated by the transformer itself. Generally, an external resonant inductor is added to meet the requirements. This method increases the size of the power supply and the cost, which is especially limiting when the size of the circuit board is limited.
[0003] Therefore, in view of the above situation, there is an urgent need to provide a high-power U-shaped output pin LLC planar transformer that does not require an external resonant inductor to overcome the shortcomings in current practical applications. Utility Model Content
[0004] The purpose of this invention is to provide a high-power U-shaped output pin LLC planar transformer that does not require an external resonant inductor, thereby solving the problems mentioned in the background art.
[0005] This invention is implemented as follows: a high-power U-shaped output LLC planar transformer without the need for an external resonant inductor is included. It comprises a magnetic core, a main transformer coil, a PCB, an output component, and a base connected to the magnetic core. The main transformer coil and the PCB are disposed inside the magnetic core. The output end of the PCB is connected to the output component. A resonant coil is also disposed at the bottom of the magnetic core.
[0006] As a further embodiment of this utility model, the base is assembled with the PCB, main transformer coil and magnetic core by means of adhesive dispensing.
[0007] As a further embodiment of this invention, the output component is a U-shaped foot.
[0008] As a further embodiment of this utility model, the U-shaped foot is made of copper-clad aluminum.
[0009] As a further aspect of this utility model: the base adopts an embedded magnetic core to achieve a robust overall structure, better current shunting effect, and lower temperature rise when a large current passes through; the output component uses copper-clad aluminum material to reduce costs.
[0010] As a further embodiment of this utility model: the PCB and the main transformer coil are alternately stacked four times to form a composite structure. The alternating four-times combination strengthens the coupling between the primary and secondary windings and improves product efficiency.
[0011] As a further embodiment of this utility model: the PCB adopts multi-layer through holes, and the output end is connected to a U-shaped copper-clad aluminum foot.
[0012] Compared with the prior art, the beneficial effects of this utility model are as follows:
[0013] 1. Small size: Combining the main transformer with the resonant inductor eliminates the need for an external resonant inductor, thus reducing the overall size;
[0014] 2. Performance is easy to achieve: The resonant inductor can be adjusted according to circuit requirements. The base, PCB, main transformer coil and magnetic core are assembled by adhesive fixing. The overall structure is compact, and the product performance, safety regulations, mechanical strength and size are easier to meet.
[0015] 3. Good product consistency: The materials used are simple and the assembly is convenient, which can greatly reduce the large fluctuations in product performance caused by inconsistencies in materials and manual operation;
[0016] 4. Low cost: The product has a pre-reserved ventilation channel at the bottom and the output components are made of copper-clad aluminum to reduce costs. The overall cost is about 25% lower than that of adding an external resonant inductor. Attached Figure Description
[0017] Figure 1 This is a schematic diagram of the structure of this utility model.
[0018] Figure 2 for Figure 1 A schematic diagram of the right-side structure.
[0019] In the attached diagram: 1-Magnetic core, 2-Base, 3-Output component, 4-Main transformer coil, 5-PCB, 6-Resonant coil. Detailed Implementation
[0020] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit the present utility model.
[0021] The specific implementation of this utility model will be described in detail below with reference to specific embodiments.
[0022] Please see Figure 1 and Figure 2The present invention provides a high-power U-shaped output LLC planar transformer without external resonant inductor. The high-power U-shaped output LLC planar transformer without external resonant inductor includes a magnetic core 1, a main transformer coil 4, a PCB 5, an output component 3, and a base 2 connected to the magnetic core 1. The main transformer coil 4 and the PCB 5 are disposed inside the magnetic core 1. The output end of the PCB 5 is connected to the output component 3. A resonant coil 6 is also disposed at the bottom of the magnetic core 1.
[0023] The base 2 is assembled with the PCB 5, the main transformer coil 4 and the magnetic core 1 by means of adhesive dispensing.
[0024] In embodiments of this invention, the transformer can be used in high-power power supplies such as UPS, energy storage, and charging piles. The resonant inductor design utilizes a separate magnetic core tightly integrated with the main transformer at the bottom of the product. Compared to the prior art, this invention has at least the following advantages:
[0025] 1. Small size: Combining the main transformer with the resonant inductor eliminates the need for an external resonant inductor, thus reducing the overall size;
[0026] 2. Performance is easy to achieve: The resonant inductor can be adjusted according to the circuit requirements. The base 2, PCB5, main transformer coil 4 and magnetic core 1 are assembled by adhesive fixing. The overall structure is compact, and the product performance, safety regulations, mechanical strength and size are easier to meet.
[0027] 3. Good product consistency: The materials used are simple and the assembly is convenient, which can greatly reduce the large fluctuations in product performance caused by inconsistencies in materials and manual operation;
[0028] 4. Low cost: The product has a pre-reserved ventilation channel at the bottom, and the output component 3 is made of copper-clad aluminum to reduce costs. The overall cost is about 25% lower than that of adding an external resonant inductor.
[0029] In one embodiment of this utility model, please refer to Figure 1 and Figure 2 The output component 3 has a U-shaped foot;
[0030] The U-shaped foot is made of copper-clad aluminum, which has a better shunting effect and a lower temperature rise when a large current passes through; the output component 3 is made of copper-clad aluminum to reduce costs.
[0031] The base 2 is embedded with a magnetic core 1 to achieve a robust overall structure;
[0032] The PCB5 and the main transformer coil 4 are alternately stacked four times to form a composite structure. The alternating four-times combination strengthens the coupling between the primary and secondary sides and improves product efficiency.
[0033] The PCB5 uses multi-layer through holes, and the output end is connected to a U-shaped copper-clad aluminum lead.
[0034] In this utility model, unless otherwise explicitly specified and limited, the terms "sliding," "rotating," "fixed," and "equipped" should be interpreted broadly. For example, they can refer to welded connections, bolted connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.
[0035] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.
Claims
1. A high-power U-shaped output LLC planar transformer without external resonant inductor, comprising a magnetic core (1), a main transformer coil (4), a PCB (5), an output component (3), and a base (2) connected to the magnetic core (1), characterized in that, The main transformer coil (4) and PCB (5) are located inside the magnetic core (1). The output end of the PCB (5) is connected to the output component (3). A resonant coil (6) is also provided at the bottom of the magnetic core (1).
2. The high-power U-shaped output pin LLC planar transformer without external resonant inductor as described in claim 1, characterized in that, The base (2) is assembled with the PCB (5), the main transformer coil (4) and the magnetic core (1) by means of adhesive dispensing.
3. The high-power U-shaped output pin LLC planar transformer without external resonant inductor as described in claim 1, characterized in that, The output component (3) has a U-shaped foot.
4. The high-power U-shaped output pin LLC planar transformer without external resonant inductor as described in claim 3, characterized in that, The U-shaped foot is made of copper-clad aluminum.
5. The high-power U-shaped output pin LLC planar transformer without external resonant inductor as described in claim 1, characterized in that, The base (2) is embedded with a magnetic core (1) to achieve a solid overall structure.
6. The high-power U-shaped output pin LLC planar transformer without external resonant inductor as described in claim 1, characterized in that, The PCB (5) and the main transformer coil (4) are stacked alternately four times to form a composite structure.
7. The high-power U-shaped output pin LLC planar transformer without external resonant inductor as described in claim 1 or 6, characterized in that, The PCB (5) uses multi-layer through-holes.