A flat high-power efficient integrated OBC transformer for vehicle
By designing an integrated OBC transformer, using a split-slot heat dissipation partition and flat wire windings, the problems of numerous components and poor heat dissipation in existing OBC transformers are solved, achieving high efficiency and flattening, and simplifying the installation process.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- CHENGDU JINZHICHUAN ELECTRONICS
- Filing Date
- 2025-06-26
- Publication Date
- 2026-06-16
Smart Images
Figure CN224366633U_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 integrated OBC transformer. Background Technology
[0002] On-board chargers (OBCs) are crucial components of new energy vehicles. OBC transformers, including the main transformer and resonant inductor, are currently mostly designed as separate components, resulting in a large number of components, large board space, complex installation, and poor heat dissipation. Furthermore, they often require external bases for positioning and pin fixing, increasing component thickness. Inconsistent operating efficiency across different frequencies prevents consistent high-efficiency output across all frequency bands. Facing intense competition in the automotive industry, high reliability, small size, and light weight have become key development directions for automotive electronic component manufacturers, rendering existing OBC transformer circuit designs inadequate. Utility Model Content
[0003] To address the problems of existing OBC transformers, such as a large number of components, large board area, poor heat dissipation, the need for additional bases, and inability to achieve high-efficiency output across all frequency bands, this utility model provides a vehicle-mounted flat high-power high-efficiency integrated OBC transformer.
[0004] This utility model provides the following technical solution: a vehicle-mounted flat high-power high-efficiency integrated OBC transformer, comprising:
[0005] The magnetic core includes three closed magnetic circuit structures connected in sequence and a dividing slit. The dividing slit is provided with a heat dissipation baffle, and the heat dissipation baffle divides each closed magnetic circuit structure into two parts. The heat dissipation baffle is provided with a first protrusion, and the first protrusion is provided with a pin hole.
[0006] The winding includes a first inductor winding, a transformer winding, and a second inductor winding, which are respectively wound on three closed magnetic circuit structures. The first inductor winding and the second inductor winding are respectively disposed on both sides of the transformer winding. The transformer winding includes a primary winding and a secondary winding. The primary winding is connected in series with the first inductor winding, and the secondary winding is connected in series with the second inductor winding.
[0007] Preferably, the magnetic core includes four parallel base plates and magnetic pillars disposed between any two adjacent base plates. The magnetic pillars include a pair of first magnetic pillars, a pair of second magnetic pillars, and a pair of third magnetic pillars. The pair of first magnetic pillars and the two adjacent base plates form a closed magnetic circuit structure in the shape of a square. The pair of second magnetic pillars and the two adjacent base plates form a closed magnetic circuit structure in the shape of a square. The pair of third magnetic pillars and the two adjacent base plates form a closed magnetic circuit structure in the shape of a square.
[0008] Preferably, the device further includes a frame sleeved on the magnetic post, the windings are all wound on the frame, a gap is provided between the frame and the magnetic post, and the frame is provided with a glue-filling port communicating with the gap.
[0009] Preferably, the first magnetic column, the second magnetic column, and the third magnetic column are each provided with a plurality of air gap pads along the length direction.
[0010] Preferably, the heat dissipation partition includes a strip-shaped portion corresponding to the magnetic column and a connecting portion corresponding to the base plate.
[0011] Preferably, the heat dissipation partition further includes an extension portion corresponding to the base plate.
[0012] Preferably, the heat dissipation partition is further provided with a plurality of second protrusions, and the second protrusions are provided with positioning holes.
[0013] Preferably, the secondary winding is wound outside the primary winding.
[0014] Preferably, all windings are made of flat wire.
[0015] The beneficial effects of this utility model are as follows: It integrates a transformer and a resonant inductor, with a resonant inductor connected in series between the primary and secondary windings. Simultaneously, the leakage inductance between the primary and secondary windings is used as the resonant inductor, ensuring that the transformer achieves an efficiency of over 98.5% across all frequency bands. The heat dissipation plate enhances heat dissipation, increasing the internal heat dissipation speed of the magnetic core and improving the device's operating power, thereby increasing the device's volumetric power density. The heat dissipation plate features pin holes, replacing the base in existing technologies, effectively reducing product height and achieving a flattened design. Air gap gaskets divide the magnetic column into multiple segments, preventing concentrated heat generation. The frame has a potting port, facilitating the injection of thermally conductive adhesive into the gaps, improving thermal conductivity, and effectively isolating the windings and magnetic core, increasing the creepage distance. Attached Figure Description
[0016] Figure 1 A three-dimensional diagram of one embodiment of an OBC transformer.
[0017] Figure 2 This is a cross-sectional view of one embodiment of an OBC 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 a heat dissipation partition.
[0020] Figure 5 This is a schematic diagram of one embodiment of the skeleton.
[0021] Reference numerals: 11, First magnetic post; 12, Second magnetic post; 13, Third magnetic post; 14, Base plate; 15, Air gap pad; 20, Heat dissipation plate; 21, Strip-shaped part; 22, Connecting part; 23, Extended part; 24, First protrusion; 241, Pin hole; 25, Second protrusion; 251, Positioning hole; 31, First inductor winding; 32, Second inductor winding; 33, Primary winding; 34, Secondary winding; 40, Frame; 41, Potting port. Detailed Implementation
[0022] 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.
[0023] This utility model provides, for example Figure 1-5 The image shows a vehicle-mounted flat high-power high-efficiency integrated OBC transformer, including a magnetic core, a frame, and windings.
[0024] Please refer to Figure 3 In this embodiment, the magnetic core includes four parallel base plates 14 and magnetic pillars disposed between any two adjacent base plates 14. Specifically, the magnetic pillars include a pair of first magnetic pillars 11, a pair of second magnetic pillars 12, and a pair of third magnetic pillars 13. The pair of first magnetic pillars 11 are connected to the two adjacent base plates 14 to form a first U-shaped closed magnetic circuit structure, the pair of second magnetic pillars 12 are connected to the two adjacent base plates 14 to form a second U-shaped closed magnetic circuit structure, and the pair of third magnetic pillars 13 are connected to the two adjacent base plates 14 to form a third U-shaped closed magnetic circuit structure. The first and second U-shaped closed magnetic circuit structures share a base plate, and the second and third U-shaped closed magnetic circuit structures also share a base plate. Multiple air gap pads 15 are sequentially arranged along the length of each of the first magnetic pillars 11, second magnetic pillars 12, and third magnetic pillars 13, dividing the magnetic pillar into multiple segments to disperse heat dissipation and avoid concentrated heat generation. The air gap pads can be ceramic pads with high thermal conductivity. In other embodiments, a closed magnetic circuit structure consisting of three sequentially connected elements may be used, such as a circular ring magnetic core or a rhomboid ring magnetic core.
[0025] The magnetic core also has dividing slots, and heat dissipation baffles 20 are installed in the dividing slots. Please refer to... Figure 2 The heat dissipation partition 20 extends horizontally, dividing all the base plates 14, the first magnetic pillar 11, the second magnetic pillar 12, and the third magnetic pillar 13 into two parts. Both parts are bonded to the heat dissipation partition 20, and the division ratio of the two parts can be flexibly selected according to design requirements. The heat dissipation partition 20 is made of insulating and heat-dissipating materials, such as ceramic sheets, to quickly dissipate heat from the magnetic core, improve the operating power of the device, and thus improve the volumetric power density of the device.
[0026] In this embodiment, the shape of the heat dissipation baffle 20 can be referred to Figure 4 It includes a strip-shaped portion 21 corresponding to the magnetic column, a connecting portion 22 corresponding to the base plate 14, and an extension portion 23. In other embodiments, the shape of the magnetic core can be adjusted in size or shape according to the actual power design. For example, the portion of the base plate 14 extending outward beyond the magnetic column can be removed, and the shape of the heat dissipation baffle 20 basically corresponds to the cross-section of the magnetic core, thus excluding the extension portion 23.
[0027] Furthermore, the heat dissipation baffle 20 is also provided with a first protrusion 24 and a second protrusion 25. Please refer to... Figure 4 The first protrusion 24 is provided with a pin hole 241 for fixing the winding pins, replacing the function of the base in the prior art, effectively reducing the product height and realizing product flattening; the second protrusion 25 is provided with a positioning hole 251, which facilitates the installation and positioning of the entire product and is more conducive to automated processing.
[0028] Please refer to Figure 1 , 2 The windings include a first inductor winding 31, a second inductor winding 32, and a transformer winding. The transformer winding includes a primary winding 33 and a secondary winding 34. A pair of first magnetic posts 11 are each wound with the first inductor winding 31, forming a resonant inductor. A pair of second magnetic posts 12 are each wound with the transformer winding, with the primary winding 33 wound on the inner side and the secondary winding 34 wound on the outer side, forming the main transformer. The leakage inductance of the main transformer can be used as the resonant inductor. A pair of third magnetic posts 13 are each wound with the second inductor winding 32, forming a resonant inductor. Furthermore, the primary winding 33 is connected in series with the first inductor winding 31, and the secondary winding 34 is connected in series with the second inductor winding 32, ensuring that the OBC transformer achieves an efficiency of over 98.5% across all frequency bands.
[0029] The winding can use flat film wrapping with high overlap, which can avoid the space waste caused by using round wire, maximize the use of core space, ensure safety creepage, and avoid the additional increase in device size due to insufficient safety distance.
[0030] The OBC transformer also includes a bobbin 40 fitted onto the magnetic core, and all windings are wound on the bobbin 40. Please refer to... Figure 2 , 5 A gap is provided between the skeleton 40 and the magnetic column, and each side of the skeleton 40 is provided with a glue-filling port 41 communicating with the gap, so as to facilitate the filling of thermally conductive glue into the gap, improve the thermal conductivity, and effectively isolate the winding and the magnetic core, thereby increasing the creepage distance.
[0031] 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 integrated OBC transformer, characterized in that, include: The magnetic core includes three closed magnetic circuit structures connected in sequence and a dividing slit. The dividing slit is provided with a heat dissipation baffle, and the heat dissipation baffle divides each closed magnetic circuit structure into two parts. The heat dissipation baffle is provided with a first protrusion, and the first protrusion is provided with a pin hole. The winding includes a first inductor winding, a transformer winding, and a second inductor winding, which are respectively wound on three closed magnetic circuit structures. The first inductor winding and the second inductor winding are respectively disposed on both sides of the transformer winding. The transformer winding includes a primary winding and a secondary winding. The primary winding is connected in series with the first inductor winding, and the secondary winding is connected in series with the second inductor winding.
2. The vehicle-mounted flat high-power high-efficiency integrated OBC transformer according to claim 1, characterized in that, The magnetic core includes four parallel base plates and magnetic pillars disposed between any two adjacent base plates. The magnetic pillars include a pair of first magnetic pillars, a pair of second magnetic pillars, and a pair of third magnetic pillars. The pair of first magnetic pillars and the two adjacent base plates form a closed magnetic circuit structure in the shape of a square. The pair of second magnetic pillars and the two adjacent base plates form a closed magnetic circuit structure in the shape of a square. The pair of third magnetic pillars and the two adjacent base plates form a closed magnetic circuit structure in the shape of a square.
3. The vehicle-mounted flat high-power high-efficiency integrated OBC transformer according to claim 2, characterized in that, It also includes a frame fitted onto the magnetic post, the windings are all wound on the frame, a gap is provided between the frame and the magnetic post, and the frame is provided with a glue-filling port communicating with the gap.
4. The vehicle-mounted flat high-power high-efficiency integrated OBC transformer according to claim 2, characterized in that, The first magnetic column, the second magnetic column, and the third magnetic column are each provided with multiple air gap pads along their length.
5. A vehicle-mounted flat high-power high-efficiency integrated OBC transformer according to claim 2, characterized in that, The heat dissipation baffle includes a strip-shaped portion corresponding to the magnetic column and a connecting portion corresponding to the base plate.
6. The vehicle-mounted flat high-power high-efficiency integrated OBC transformer according to claim 5, characterized in that, The heat dissipation partition also includes an extension portion corresponding to the base plate.
7. The on-board flat high-power high-efficiency integrated OBC transformer according to claim 1, characterized in that, The heat dissipation baffle is also provided with a plurality of second protrusions, and the second protrusions are provided with positioning holes.
8. The on-board flat high-power high-efficiency integrated OBC transformer according to claim 1, characterized in that, The secondary winding is wound outside the primary winding.
9. A vehicle-mounted flat high-power high-efficiency integrated OBC transformer according to claim 1, characterized in that, All windings use flat wire.