Ultrathin high-power LLC resonant main transformer for module power supply

Abstract

The utility model discloses an ultrathin high-power LLC resonant main transformer for a module power supply. The ultrathin high-power LLC resonant main transformer comprises an ER type wide-temperature low-loss flat plate magnetic core, the primary side line cake is wound on the magnetic core; the secondary copper sheet is arranged on the magnetic core; the primary line cake adopts a special three-layer line structure; and the secondary copper sheet is led out through a copper nail to form an SMT (Surface Mount Technology) mounting pin. According to the utility model, the special ER type flat plate magnetic core is adopted, the window utilization rate is improved, and the overall volume is reduced; the primary side adopts a special three-layer wire cake structure, the insulating property is improved, the safety standard requirement is met, the secondary side adopts an optimally designed copper sheet structure, the conductor loss is reduced, and the heat dissipation capability is improved; the upper and lower surfaces are flat, so that combination with a radiator is facilitated, and the radiating efficiency is improved; under the same power condition, the size is reduced by 1 / 3-1 / 2, and the power density is remarkably improved.

Description

Technical Field

[0001] This utility model relates to the field of electronic components technology, and in particular to an ultra-thin high-power LLC resonant main transformer for modular power supplies. Background Technology

[0002] LLC resonant topology, as an advanced switching power supply technology, has gained widespread recognition and application in high-power power supply applications due to its significantly low switching losses. In power electronic systems, LLC resonant circuits can achieve zero-voltage turn-on (ZVS) of the switching transistors, greatly reducing switching losses and improving system efficiency, making it an ideal choice for high-power scenarios.

[0003] However, the transformer structures used in traditional LLC resonant circuits have some significant shortcomings. These traditional transformers typically employ conventional magnetic core and winding structures, leading to limitations in the following aspects:

[0004] First, traditional transformer structures have low window utilization rates. In conventional EE, EI, or other shaped cores, there is significant waste in the winding fill space, failing to fully utilize the core window area. This inefficient space utilization necessitates larger cores for the same power rating, directly impacting the overall size of the transformer.

[0005] Secondly, traditional transformers generally have a large finished structure. Due to limitations in winding structure design, coupled with the additional space required to meet insulation requirements, traditional transformers are often bulky in high-power applications. Especially in AC-DC conversion scenarios, the size of transformers is further increased to meet the stringent insulation requirements of safety standards.

[0006] Furthermore, the size of traditional transformers directly leads to an increase in the overall size of the power module. In the trend of miniaturization and lightweight design in modern electronic systems, the size of the power module has become a bottleneck limiting system integration. Large transformers occupy valuable space resources, restricting the layout flexibility of the power module and the design freedom of the entire system.

[0007] In summary, traditional switching power supply transformer structures have shortcomings in terms of window utilization, size, space occupation, and heat dissipation, resulting in larger power module sizes and higher costs, making it difficult to meet the needs of modern high-power-density power systems. These issues restrict the widespread application of LLC resonant topologies in more high-power-density application scenarios, necessitating the development of new transformer structures to overcome these technical bottlenecks. Utility Model Content

[0008] The purpose of this invention is to address the shortcomings of existing technologies by proposing an ultra-thin, high-power LLC resonant main transformer for modular power supplies.

[0009] To achieve the above objectives, the present invention adopts the following technical solution:

[0010] An ultra-thin, high-power LLC resonant main transformer for modular power supplies includes:

[0011] ER type wide-temperature low-loss flat magnetic core;

[0012] The original edge wire disc wound on the magnetic core;

[0013] Secondary copper strips are mounted on the magnetic core;

[0014] The original edge-lined pattern uses a special three-layer line structure;

[0015] The secondary copper sheet is led out through copper pins to form SMT mounting leads.

[0016] Furthermore, the magnetic core has an ER-type flat plate structure, characterized by flat upper and lower surfaces.

[0017] Furthermore, the three-layer wire structure of the primary side wire disc includes multiple layers of insulating material around the conductor to enhance the insulation performance between the primary and secondary sides.

[0018] Furthermore, the thickness of the secondary copper sheet is designed according to the output current.

[0019] Furthermore, the transformer's volume is reduced by 1 / 3 to 1 / 2 compared to a conventional transformer of the same power.

[0020] Furthermore, the transformer is suitable for a power range of 500W to 6KW.

[0021] The beneficial effects of this utility model are as follows:

[0022] 1. Utilizing a special ER-type flat magnetic core improves window utilization and reduces overall size; the primary side employs a special three-layer wire disc structure, enhancing insulation performance and meeting safety standards; the secondary side uses an optimized copper sheet structure, reducing conductor loss and improving heat dissipation; the overall flat design with flat top and bottom surfaces facilitates integration with heat sinks, improving heat dissipation efficiency; under the same power conditions, the volume is reduced by 1 / 3 to 1 / 2, significantly increasing power density; SMT mounting improves assembly efficiency and reduces production costs; optimized structural design reduces leakage inductance and improves energy transfer efficiency.

[0023] The above description is merely an overview of the technical solution of this utility model. In order to better understand the technical means of this utility model and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this utility model more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0024] Figure 1 A schematic diagram of the magnetic core structure of an ultra-thin high-power LLC resonant main transformer for a modular power supply proposed in this utility model.

[0025] Figure 2 This is a schematic diagram of the primary side wire disc structure of an ultra-thin high-power LLC resonant main transformer for a modular power supply proposed in this utility model.

[0026] Figure 3 This is a schematic diagram of the secondary copper sheet structure of an ultra-thin high-power LLC resonant main transformer for a modular power supply proposed in this utility model.

[0027] Figure 4 This is a schematic diagram of the finished product structure of an ultra-thin high-power LLC resonant main transformer for modular power supply proposed in this utility model.

[0028] In the diagram: 1. ER type wide-temperature low-loss flat magnetic core; 2. Primary side wire disc; 3. Secondary side copper sheet. Detailed Implementation

[0029] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0030] This embodiment provides an ultra-thin LLC resonant main transformer, which is suitable for high-power modular power supplies, especially for scenarios requiring high power density. The structure and working principle of this invention will be described in detail below with reference to the accompanying drawings.

[0031] Overall structure

[0032] like Figure 4 As shown, the LLC resonant main transformer of this invention mainly consists of three parts: an ER-type wide-temperature, low-loss flat plate magnetic core 1, a primary-side wire disc 2, and a secondary-side copper sheet 3. These three parts are assembled into a complete transformer structure through a carefully designed assembly method, achieving the technical effects of small size and high power density.

[0033] magnetic core structure

[0034] like Figure 1 As shown, this utility model employs a specially designed ER-type wide-temperature, low-loss flat magnetic core 1. This magnetic core is made of high-quality soft magnetic material and has the following characteristics:

[0035] The flat-plate structure design reduces the overall height of the transformer;

[0036] Wide temperature range ensures stable performance within an operating temperature range of -40℃ to +125℃;

[0037] Low loss characteristics, with low hysteresis loss and eddy current loss under high frequency operating conditions (typically 100kHz-500kHz).

[0038] The ER-type structure provides a larger effective window area, improving the space utilization of the winding.

[0039] The cross-sectional area of ​​the central column of the magnetic core varies depending on the power level. This invention can provide a variety of specifications to meet the application needs of different power levels from 500W to 6KW.

[0040] Primary winding structure

[0041] like Figure 2 As shown, the primary winding of this invention adopts a special three-layer coil structure 2. This coil winding has the following characteristics:

[0042] The three-layer wire technology is adopted, which means wrapping multiple layers of insulating material around the conductor to enhance the insulation performance between the primary and secondary sides and meet the enhanced insulation requirements in AC-DC scenarios;

[0043] The coil adopts a flattened design, which reduces the thickness of the winding;

[0044] The winding method has been optimized to reduce leakage inductance and improve energy transfer efficiency;

[0045] An ideal voltage conversion ratio can be achieved by precisely controlling the turns ratio.

[0046] The original design of the edge circuit fully considers the characteristics of the LLC resonant circuit, enabling the transformer to operate in a resonant state and reducing switching losses.

[0047] Secondary winding structure

[0048] like Figure 3 As shown, the secondary winding of this utility model adopts a copper sheet structure 3, which has the following characteristics:

[0049] Using copper sheets of appropriate thickness instead of traditional wires significantly reduces conductor resistance and copper loss;

[0050] The copper sheet features a special shape design that optimizes current distribution and reduces localized hot spots;

[0051] By leading the wires out with copper pins, pins that can be surface-mounted (SMT) are formed, improving assembly efficiency and reliability.

[0052] The copper sheet structure increases the heat dissipation area, thereby improving the transformer's heat dissipation capacity.

[0053] The thickness and shape of the secondary copper sheet are optimized according to the output current to ensure good performance even under high current conditions.

[0054] Assembly process

[0055] The assembly process of the LLC resonant main transformer of this utility model is as follows:

[0056] First, the original edge wire disc 2 is wound onto the central column of the magnetic core 1 according to the design requirements;

[0057] Then, the secondary copper sheet 3 is placed in the designed position and combined with the magnetic core;

[0058] High-temperature insulating materials are used to isolate the primary and secondary sides;

[0059] Assemble and fix the upper and lower parts of the magnetic core;

[0060] The wires on the primary and secondary sides are led out using copper pins to form SMT mounting pins;

[0061] Conduct electrical performance tests and insulation strength tests to ensure that the product performance meets the requirements.

[0062] Working principle

[0063] The LLC resonant main transformer of this invention operates in an LLC resonant topology circuit, and its working principle is as follows:

[0064] The LLC resonant circuit creates resonance between the resonant capacitor and the leakage inductance and magnetizing inductance of the transformer by controlling the on-time and frequency of the primary-side switching transistor;

[0065] When the circuit operates near the resonant frequency, the switching transistor can achieve zero-voltage turn-on (ZVS), which significantly reduces switching losses.

[0066] The current in the original edge disc generates an alternating magnetic field through the magnetic core;

[0067] An alternating magnetic field induces a current in the secondary copper sheet, thus enabling energy transfer.

[0068] Through optimized copper design, the LLC resonant main transformer of this invention has the following typical parameters for different power levels:

[0069] Power range: 500W-6KW;

[0070] Operating frequency: 100kHz-500kHz;

[0071] Primary voltage: 300V-400V DC;

[0072] Secondary voltage: Customizable according to application requirements, typical value is 12V-48V DC;

[0073] Insulation withstand voltage: >3000V AC;

[0074] Operating temperature: -40℃ to +125℃;

[0075] Size reduction: 1 / 3 to 1 / 2 smaller than traditional structures;

[0076] Height: More than 40% smaller than traditional transformers. Plate structure for efficient energy transfer to the load.

[0077] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A thin, high-power LLC resonant main transformer for modular power supplies, characterized in that, include: ER type wide temperature low loss flat plate magnetic core (1); The original edge wire disc (2) is wound on the magnetic core (1); The secondary copper sheet (3) is disposed on the magnetic core (1); The original edge line cake (2) adopts a special three-layer line structure; The secondary copper sheet (3) is led out through copper pins to form SMT mounting pins.

2. The ultra-thin high-power LLC resonant main transformer for modular power supplies according to claim 1, characterized in that, The magnetic core (1) is an ER-type flat plate structure with flat upper and lower surfaces.

3. The ultra-thin high-power LLC resonant main transformer for modular power supplies according to claim 1, characterized in that, The three-layer wire structure of the primary edge wire cake (2) includes multiple layers of insulating material around the conductor, which are used to enhance the insulation performance between the primary edge and the secondary edge.

4. The ultra-thin high-power LLC resonant main transformer for modular power supplies according to claim 1, characterized in that, The thickness of the secondary copper sheet (3) is designed according to the output current.

5. The ultra-thin high-power LLC resonant main transformer for modular power supplies according to claim 1, characterized in that, The volume of the transformer is reduced by 1 / 3 to 1 / 2 compared to a conventional transformer of the same power.

6. The ultra-thin high-power LLC resonant main transformer for modular power supplies according to claim 1, characterized in that, The transformer is suitable for a power range of 500W to 6KW.

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