Vehicle-mounted flat high-power efficient DCDC transformer
By using a flat design and optimizing the winding structure, the problems of large package size and heat dissipation of vehicle-mounted DC-DC transformers have been solved, achieving efficient heat dissipation and miniaturization, thus improving working efficiency.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- CHENGDU JINZHICHUAN ELECTRONICS
- Filing Date
- 2025-06-17
- Publication Date
- 2026-06-12
AI Technical Summary
Existing vehicle-mounted DC-DC transformers have large package sizes under high-power designs, making it difficult to effectively dissipate internal heat, resulting in severe overheating and low operating efficiency.
It adopts a flat design, using sheet-like primary and secondary windings. The secondary winding is equipped with a heat sink, and the space utilization and heat dissipation are optimized through the pin frame and insulating partition structure, combined with the potting port to dissipate heat.
It improves space utilization, reduces heat generation during high-frequency operation, enhances heat dissipation efficiency, and improves device efficiency and miniaturization design.
Smart Images
Figure CN224355087U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of transformer technology, and in particular to a vehicle-mounted flat high-power high-efficiency DC-DC transformer. Background Technology
[0002] DC-DC transformers are crucial components of on-board chargers (OBCs). Their primary windings typically use triple-insulated wire or film-coated wire, while the secondary windings generally use copper sheets, with heat dissipation achieved through external cooling channels. However, under high-power design requirements, the combined effects of wasted space due to round wire and external heat dissipation issues result in large overall transformer packages, significant heat generation, and the inability to dissipate internal heat effectively after prolonged operation, leading to low device efficiency. Utility Model Content
[0003] To address the problems of large transformer package size and difficulty in dissipating internal heat in existing technologies, this utility model provides a vehicle-mounted flat high-power and high-efficiency DC-DC transformer.
[0004] This utility model provides the following technical solution: a vehicle-mounted flat high-power high-efficiency DC-DC transformer, comprising:
[0005] The magnetic core includes two base plates, a central column disposed between the two base plates, and multiple side columns. The multiple side columns are disposed around the central column, and two adjacent side columns and the two base plates form a window.
[0006] The winding includes a primary winding and a secondary winding stacked at intervals along the axial direction of the central column; the primary winding includes a primary metal sheet surrounding the central column and an insulating layer coated on the surface of the primary metal sheet, and the primary metal sheet is also provided with two primary connecting portions; the secondary winding includes a secondary metal sheet surrounding the central column, the secondary metal sheet extending out of the window and connected to a heat sink, and the secondary metal sheet is also provided with two secondary connecting portions.
[0007] Preferably, the magnetic core includes four side posts, which together with two base plates form four windows. The secondary winding includes three heat sinks, with two secondary winding connections protruding from one window and the three heat sinks protruding from the other three windows respectively.
[0008] Preferably, the secondary winding includes a first secondary winding and a second secondary winding stacked at intervals, and the primary winding is disposed between adjacent first secondary windings and second secondary windings; one secondary connection part of the first secondary winding is disposed in the center of the window, and the other secondary connection part is disposed on the left side of the window; one secondary connection part of the second secondary winding is disposed in the center of the window, and the other secondary connection part is disposed on the right side of the window.
[0009] Preferably, the primary winding is a PCB board.
[0010] Preferably, the heat sink extends along the edge of the base plate, and a plurality of the heat sinks surround the magnetic core.
[0011] Preferably, it also includes a base disposed on the base plate, the base being provided with multiple pins; the two primary side connecting parts are each electrically connected to two pins, and the two secondary side connecting parts are each electrically connected to two pins.
[0012] Preferably, the pin extends along the axial direction of the central column.
[0013] Preferably, the device further includes a pin frame disposed on one side of the magnetic core, the pin frame having a plurality of insulating partitions that separate adjacent pins.
[0014] Preferably, the pin frame has a potting port on the side facing the magnetic core.
[0015] The beneficial effects of this utility model are: both the primary winding and the secondary winding adopt a sheet structure, which has a higher space utilization rate compared with the prior art, and is more conducive to the flattening and miniaturization of the device, and generates less heat when operating at high frequency; the magnetic core is provided with multiple windows, and the secondary winding protrudes out of the windows and is provided with a heat sink, which can quickly conduct heat out of the transformer, enhance heat dissipation efficiency, and improve the working efficiency of the device. Attached Figure Description
[0016] Figure 1 This is a schematic diagram of one embodiment of a transformer.
[0017] Figure 2 This is a cross-sectional view of one embodiment of a transformer.
[0018] Figure 3 This is a schematic diagram of one embodiment of the magnetic core.
[0019] Figure 4 This is a schematic diagram of one embodiment of the primary winding.
[0020] Figure 5 This is a schematic diagram of one embodiment of the first secondary winding.
[0021] Figure 6 This is a schematic diagram of one embodiment of the second secondary winding.
[0022] Reference numerals: 11, base plate; 12, center post; 13, side post; 14, window; 21, primary winding; 211, primary connection part; 22, first secondary winding; 221, secondary metal sheet; 222a, secondary connection part; 222b, secondary connection part; 223, heat sink; 23, second secondary winding; 231a, secondary connection part; 231b, secondary connection part; 232, heat sink; 30, base; 31, pin; 40, pin frame; 41, insulating partition; 42, potting port. Detailed Implementation
[0023] The embodiments of this utility model will be described in more detail below with reference to the accompanying drawings and reference numerals, so that those skilled in the art can implement them after reading this specification. It should be understood that the specific embodiments described herein are only for explaining this utility model and are not intended to limit this utility model.
[0024] This utility model provides, for example Figure 1 The vehicle-mounted flat high-power high-efficiency DC-DC transformer shown includes a magnetic core, windings, lead frame and base.
[0025] Please refer to Figure 2 , 3 The magnetic core includes two base plates 11, a central post 12 disposed between the two base plates 11, and four side posts 13. The four side posts 13 are disposed around the central post, and adjacent two side posts 13 and the two base plates 11 form a window 14. The four side posts 13 and the two base plates 11 together form four windows 14. This utility model does not limit the number of side posts 13, and the number can be determined according to design requirements.
[0026] Please refer to Figure 2 The winding includes a primary winding 21 and a secondary winding that are stacked at intervals along the axial direction of the central column 12. The secondary winding includes a first secondary winding 22 and a second secondary winding 23. The first and second secondary windings are also stacked at intervals, and a primary winding 21 is provided between adjacent first and second secondary windings.
[0027] The primary winding 21 includes a primary metal sheet surrounding the center post 12 and an insulating layer coated on the surface of the primary metal sheet. In the structure where the primary winding 21 and the secondary winding are stacked at intervals, the insulating layer ensures the creepage distance specified in safety regulations. In this embodiment, please refer to... Figure 4The primary winding 21 is in the form of a PCB board, with its primary metal sheet arranged on the PCB board. The number of turns, width, and thickness of the primary metal sheet can be freely adjusted according to design requirements. The size and shape of the primary winding can be adjusted according to different magnetic cores, making full use of the space of the magnetic core. When the transformer product needs to operate at high frequency, the thickness of the primary metal sheet can be reduced, resulting in less heat generation at high frequencies and contributing to the miniaturization design of the product. Two primary connecting parts 211 are respectively provided at both ends of the primary metal sheet. The two primary connecting parts 211 protrude from a window 14, and the primary connecting parts 211 are designed with a U-shaped groove to facilitate connection with the pin 31 and to snap the pin 31 into the U-shaped groove. The primary connecting parts 211 are made of conductive material.
[0028] Please refer to Figure 1 , 5 The first secondary winding 22 includes a secondary metal sheet 221 surrounding the central column 12. Two secondary connecting portions are provided on one side of the secondary metal sheet 221 corresponding to a window. These two connecting portions are integrally formed with the secondary metal sheet 221 and protrude from the window for easy connection to the pin 31. One secondary connecting portion 222a is located in the center of the window, and the other secondary connecting portion 222b is located on the left side of the window. The secondary metal sheet 221 has extensions on three sides corresponding to the other three windows. These extensions protrude from the windows and are connected to heat sinks 223, which extend along the edge of the core base plate 11. The secondary winding is typically made of copper or aluminum. A bending process can be used to integrally form the heat sink 223 with the secondary metal sheet 221, enabling rapid heat dissipation from the transformer's interior, enhancing heat dissipation efficiency, improving device operating efficiency, and further contributing to product miniaturization. Furthermore, the three heat sinks 223 surrounding the core also help reduce the impact of EMC on other nearby devices.
[0029] The structure of the second secondary winding 23 is similar to that of the first secondary winding 22. Please refer to... Figure 1 , 6 The second secondary winding 23 includes a secondary metal sheet surrounding the central column 12. Two secondary connecting parts are provided on the side of the secondary metal sheet corresponding to a window. The two secondary connecting parts protrude from the window, and one secondary connecting part 231a is located in the center of the window, while the other secondary connecting part 231b is located on the right side of the window. The secondary metal sheet is provided with extensions on the three sides corresponding to the other three windows. The extensions protrude from the windows and are connected to heat sinks 232.
[0030] The base 30 is bonded to the base plate 11, and the base 30 is provided with multiple pins 31. Each primary winding 21 has two primary connecting parts 211 electrically connected to two pins 31; each first secondary winding has two secondary connecting parts electrically connected to two pins 31, and each second secondary winding has two secondary connecting parts electrically connected to two pins 31, with the first and second secondary windings sharing a single pin. The pins 31 extend along the axial direction of the central column 12, facilitating connection to multiple primary and secondary windings stacked along the axial direction of the central column 12.
[0031] Furthermore, it also includes a pin frame 40 disposed on one side of the magnetic core. The pin frame 40 is made of insulating material and has multiple insulating partitions 41. The insulating partitions 41 separate two adjacent pins 31 to reduce safety risks. The pin frame 40 also has a potting port 42 on the side facing the magnetic core, into which thermally conductive adhesive can be poured to dissipate internal heat.
[0032] The above describes one or more embodiments of this utility model in a relatively specific and detailed manner, but it should not be construed as limiting the scope of this utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.
Claims
1. A vehicle-mounted, flat, high-power, high-efficiency DC-DC transformer, characterized in that, include: The magnetic core includes two base plates, a central column disposed between the two base plates, and multiple side columns. The multiple side columns are disposed around the central column, and two adjacent side columns and the two base plates form a window. The winding includes a primary winding and a secondary winding stacked at intervals along the axial direction of the central column; the primary winding includes a primary metal sheet surrounding the central column and an insulating layer coated on the surface of the primary metal sheet, and the primary metal sheet is also provided with two primary connecting portions; the secondary winding includes a secondary metal sheet surrounding the central column, the secondary metal sheet extending out of the window and connected to a heat sink, and the secondary metal sheet is also provided with two secondary connecting portions.
2. The vehicle-mounted flat high-power high-efficiency DC-DC transformer according to claim 1, characterized in that, The magnetic core includes four side posts, which together with two base plates form four windows. The secondary winding includes three heat sinks, with two secondary winding connections protruding from one window and the three heat sinks protruding from the other three windows.
3. The vehicle-mounted flat high-power high-efficiency DC-DC transformer according to claim 2, characterized in that, The secondary winding includes a first secondary winding and a second secondary winding stacked at intervals, and the primary winding is provided between adjacent first secondary windings and second secondary windings; one secondary connection part of the first secondary winding is located in the center of the window, and the other secondary connection part is located on the left side of the window; one secondary connection part of the second secondary winding is located in the center of the window, and the other secondary connection part is located on the right side of the window.
4. The vehicle-mounted flat high-power high-efficiency DC-DC transformer according to claim 1, characterized in that, The primary winding is a PCB board.
5. The vehicle-mounted flat high-power high-efficiency DC-DC transformer according to claim 1, characterized in that, The heat sink extends along the edge of the base plate, and multiple heat sinks surround the magnetic core.
6. The vehicle-mounted flat high-power high-efficiency DC-DC transformer according to claim 1, characterized in that, It also includes a base mounted on the base plate, the base having multiple pins; the two primary side connecting parts are each electrically connected to two pins, and the two secondary side connecting parts are each electrically connected to two pins.
7. A vehicle-mounted flat high-power high-efficiency DC-DC transformer according to claim 6, characterized in that, The pin extends along the axial direction of the central column.
8. A vehicle-mounted flat high-power high-efficiency DC-DC transformer according to claim 6, characterized in that, It also includes a pin frame disposed on one side of the magnetic core, the pin frame being provided with multiple insulating partitions that separate adjacent pins.
9. A vehicle-mounted flat high-power high-efficiency DC-DC transformer according to claim 6, characterized in that, The pin frame has a potting port on the side facing the magnetic core.