A transformer structure and its water-cooled rectifier power supply

Abstract

This utility model discloses a transformer structure and its water-cooled rectifier power supply, including a transformer assembly. A synchronous rectifier module is disposed on the left or right side of the transformer assembly, and the transformer assembly has at least two secondary sides. The synchronous rectifier module is electrically connected to the two secondary sides of the transformer assembly, respectively. Several absorption modules are stacked on the synchronous rectifier module via copper pillars, and the absorption modules are electrically connected to the synchronous rectifier module. A drive module is also disposed on the synchronous rectifier module, and the drive module is electrically connected to the synchronous rectifier module. This utility model optimizes the structure of the synchronous rectifier module, achieving full-wave rectification function with a single novel synchronous rectifier module, saving production costs and improving material utilization. Simultaneously, the installation position of the synchronous rectifier module has been changed; by placing the synchronous rectifier module on the left or right arm of the magnetic core, the influence of eddy currents is avoided.

Description

Technical Field

[0001] This utility model relates to the field of rectifier power supply technology, specifically to a transformer structure and its water-cooled rectifier power supply. Background Technology

[0002] A rectifier power supply is an electronic device or circuit that converts alternating current (AC) into direct current (DC). With the continuous development of technology, traditional rectifier power supplies are gradually failing to meet usage requirements and have many drawbacks:

[0003] (1) Traditional power supplies typically use diodes for rectification. When a diode is conducting, it has a fixed forward voltage drop. This voltage drop can cause significant power loss under high current, such as... Figure 1 As shown, to improve power supply efficiency, existing rectifier power supplies typically install a synchronization module 2' on the secondary side of transformer 1', using MOSFETs (field-effect transistors) instead of traditional rectifier diodes. This allows the switching state of the MOSFETs on the output side to be precisely synchronized with the switching state of the main power switch on the input side, thereby significantly reducing conduction losses. However, this structure also requires the installation of a synchronization module 2' on each secondary side of transformer 1', resulting in a complex structure, a large number of MOSFETs, low utilization efficiency, and difficulty in maintenance. Furthermore, the existing synchronization module 2' is fixed to the front and rear arms of the transformer core 3', making it susceptible to the eddy currents generated by the transformer core 3', which can lead to heat accumulation.

[0004] (2) Due to parasitic parameters (mainly inductance and capacitance), voltage spikes, current overshoots and oscillations are easily caused on the secondary side of transformer 1'. In order to protect the synchronization module 2', an absorption module is usually installed on the secondary side of transformer 1'. Existing absorption modules are generally connected by cables or soft copper sheets and suspended on the secondary side of transformer 1'. Not only is the voltage spike absorption effect poor and the heat dissipation effect poor, but it also occupies space and is not aesthetically pleasing. Furthermore, there is a risk of damage if it is suspended around transformer 1' for a long time.

[0005] (3) The secondary side of the traditional transformer 1' is used to install the synchronization module 2', which is usually designed as a bent structure. This results in a small contact area between the secondary side of the transformer 1' and the heat sink, which easily leads to a large amount of heat generated at the connection and difficulty in heat dissipation. Utility Model Content

[0006] The purpose of this utility model is to address the shortcomings of the existing technology by providing a transformer structure and its water-cooled rectifier power supply, thereby solving the problems mentioned in the background art.

[0007] To achieve this objective, the present invention adopts the following technical solution:

[0008] A transformer structure and its water-cooled rectifier power supply include a transformer assembly, a synchronous rectifier module disposed on the left or right side of the transformer assembly, and the transformer assembly having at least two secondary sides. The synchronous rectifier module is electrically connected to the two secondary sides of the transformer assembly, and a plurality of absorption modules are stacked on the synchronous rectifier module through copper pillars. The absorption modules are electrically connected to the synchronous rectifier module. The synchronous rectifier module is also provided with a drive module, which is electrically connected to the synchronous rectifier module.

[0009] As a preferred embodiment of the transformer structure, the synchronous rectification module includes a circuit board, a first output element, and two second output elements. The circuit board is stacked on the first output element, and the second output elements are symmetrically distributed on both sides of the first output element. The first output element has two rows of MOSFETs arranged symmetrically and parallel to each other. The circuit board has through holes, through which the MOSFETs pass and are electrically connected to the circuit board. Each row of MOSFETs is electrically connected to the second output element on the same side.

[0010] As a preferred embodiment of the transformer structure, each of the second output elements includes a flat plate base, and each of the two flat plate bases has a protrusion on its opposite side, the protrusion being electrically connected to the transformer assembly.

[0011] As a preferred embodiment of the transformer structure, the transformer assembly includes an annular magnetic core and a coil wound on the magnetic core. A conductive core is disposed through the central hole of the magnetic core along its axial direction. Conductive plates are respectively disposed at both ends of the conductive core. The plane in which the synchronous rectification module is located is parallel to the central axis of the conductive core.

[0012] As a preferred embodiment of the transformer structure, the conductive core includes a first battery core and a second battery core, wherein the first battery core and the second battery core are insulated from each other.

[0013] As a preferred embodiment of the transformer structure, the conductive plate includes a first plate, a second plate, a third plate, and a fourth plate. The two ends of the first battery cell are electrically connected to the first plate and the second plate, respectively. The two ends of the second battery cell are electrically connected to the third plate and the fourth plate, respectively. The two protrusions of the synchronous rectification module are electrically connected to the first plate and the fourth plate, respectively. The first plate and the fourth plate are configured as planar structures.

[0014] On the other hand, a water-cooled rectifier power supply is provided, including the above-mentioned transformer structure and a chassis. A first heat sink and a second heat sink are spaced apart in the chassis. A plurality of transformer assemblies are arranged between the first heat sink and the second heat sink. The transformer assemblies are spaced apart along the length direction of the first heat sink and the second heat sink. The synchronous rectification module is disposed on the first heat sink and electrically connected to it. The second circuit board and the third circuit board are respectively electrically connected to the second heat sink.

[0015] As a preferred embodiment of a water-cooled rectifier power supply, a first inductor is mounted on the first heat sink, and a second inductor and a current Hall sensor are mounted on the second heat sink. One end of the first heat sink extends outside the chassis as one of the output terminals, and one end of the second heat sink extends outside the chassis as the other output terminal.

[0016] As a preferred embodiment of a water-cooled rectifier power supply, the second heat sink is provided with an input power unit and a control system on the side away from the first heat sink, and the control system is communicatively connected to the drive module.

[0017] As a preferred embodiment of the water-cooled rectifier power supply, each of the synchronous rectifier modules is equipped with a temperature sensor, which is communicatively connected to the control system.

[0018] The beneficial effects of this utility model are:

[0019] (1) The structure of the synchronous rectification module has been optimized. The full-wave rectification function is realized through a new synchronous rectification module, which saves production costs and improves material utilization. At the same time, the installation position of the synchronous rectification module has been changed. The synchronous rectification module is installed on the first heat sink, which does not need to be tied to the transformer, thus improving the ease of replacement and maintenance. Furthermore, the synchronous rectification module is set on the left and right arms of the magnetic core, avoiding the influence of eddy currents.

[0020] (2) The structure of the absorption module has been optimized. The absorption module is stacked on the synchronization module in the form of a PCB circuit board, which realizes efficient use of space. The absorption module can be freely added or removed according to the usage requirements, and maintenance is simple and convenient. At the same time, the absorption module is connected by copper pillars, which improves the voltage peak absorption effect and reduces heat generation.

[0021] (3) The structure of the transformer assembly has been optimized. The first and fourth plates on the secondary side of the transformer assembly have been changed from the traditional bent structure to a planar structure, which increases the contact area between the secondary side of the transformer assembly and the first heat sink and the synchronous rectification module, and solves the problem of heat dissipation on the secondary side of the transformer. Attached Figure Description

[0022] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments of this utility model will be briefly described below. Obviously, the drawings described below are merely some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0023] Figure 1 This is a schematic diagram of the structure of a transformer in the prior art.

[0024] Figure 2 This is a schematic diagram of the overall structure of the transformer structure described in this utility model.

[0025] Figure 3 This is a schematic diagram of the disassembled structure of the transformer structure described in this utility model.

[0026] Figure 4 This is a schematic diagram of the synchronous rectification module described in this utility model.

[0027] Figure 5 This is a cross-sectional structural diagram of the synchronous rectification module described in this utility model.

[0028] Figure 6 This is a schematic diagram of the structure of the transformer assembly described in this utility model.

[0029] Figure 7 This is a schematic diagram of the disassembled structure of the transformer assembly described in this utility model.

[0030] Figure 8 This is a schematic diagram of the structure of the water-cooled rectifier power supply described in this utility model.

[0031] Figure 9 This is a schematic diagram of the structure of the water-cooled rectifier power supply after the chassis has been removed.

[0032] Figure 1 middle:

[0033] 1' Transformer; 2' Synchronization module; 3' Transformer core.

[0034] Figures 2 to 9 middle:

[0035] 1. Transformer assembly; 101. Magnetic core; 102. Coil; 103. Conductive core; 1031. First battery cell; 1032. Second battery cell; 104. Conductive plate; 1041. First battery board; 1042. Second battery board; 1043. Third battery board; 1044. Fourth battery board; 2. Synchronous rectification module; 21. Circuit board; 22. First output element; 23. Second output element; 231. Flat base; 232. Protrusion; 24. MOSFET; 3. Absorption module; 4. Drive module; 5. Chassis; 6. First heat sink; 7. Second heat sink; 8. First inductor; 9. Second inductor; 10. Current Hall sensor; 11. Input power supply unit; 12. Control system; 13. Temperature sensor. Detailed Implementation

[0036] The technical solution of this utility model will be further described below with reference to the accompanying drawings and specific embodiments.

[0037] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual images. They should not be construed as limiting the scope of this patent. To better illustrate the embodiments of this utility model, some components in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0038] In the accompanying drawings of this utility model, the same or similar reference numerals correspond to the same or similar components. In the description of this utility model, it should be understood that if terms such as "upper," "lower," "left," "right," "inner," and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the 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. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting this patent. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0039] In the description of this utility model, unless otherwise explicitly specified and limited, the term "connection" or similar designation indicating the connection relationship between components should be interpreted broadly. For example, it can refer to a fixed connection, a detachable connection, or an integral part; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0040] Example 1:

[0041] like Figure 2 and Figure 3 As shown, this embodiment provides a transformer structure, including a transformer assembly 1. A synchronous rectification module 2 is provided on the left or right side of the transformer assembly 1, and the transformer assembly 1 is provided with at least two secondary sides. In this embodiment, two secondary sides are preferred. The synchronous rectification module 2 is electrically connected to the two secondary sides of the transformer assembly 1 respectively. The full-wave rectification function can be realized through a new synchronous rectification module 2, which saves production costs and improves material utilization.

[0042] To avoid voltage spikes, the synchronous rectification module 2 is equipped with several absorption modules 3. In this embodiment, the absorption modules 3 are stacked on the synchronous rectification module 2 in the form of PCB circuit boards, which realizes efficient use of space. Furthermore, the absorption modules 3 can be freely added or removed according to usage requirements, and maintenance is simple and convenient. At the same time, the absorption modules 3 are electrically connected to the synchronous rectification module 2 using copper pillars, which improves the voltage spike absorption effect and reduces heat generation.

[0043] Preferably, the synchronous rectification module 2 is further provided with a drive module 4, which is electrically connected to the synchronous rectification module 2 and can provide the synchronous rectification module 2 with precise timing control, power drive amplification, real-time protection decision-making, etc.

[0044] like Figure 4 and Figure 5 As shown, the synchronous rectification module 2 in this embodiment specifically includes a circuit board 21, a first output element 22, and two second output elements 23. The circuit board 21 is stacked on the first output element 22, and the second output elements 23 are symmetrically distributed on both sides of the first output element 22. The first output element 22 has two rows of MOSFETs 24 arranged symmetrically and in parallel. The circuit board 21 has through holes through which the MOSFETs 24 pass and are electrically connected to the circuit board 21. Each row of MOSFETs 24 is electrically connected to the second output element 23 on the same side.

[0045] More specifically, each second output element 23 includes a flat plate base 231. Each of the two flat plate bases 231 has a protrusion 232 on the side that is far apart from each other. The protrusion 232 is electrically connected to the transformer assembly 1. The induced current generated by the transformer assembly 1 is conducted to the flat plate base 231 through the protrusion 232, and then to the two columns of MOSFETs 24 through the flat plate base 231, and then to the first output element 22 through the MOSFETs 24.

[0046] Preferably, the flat plate base 231 and the protrusion 232 in this embodiment are preferably designed as a single piece, and the two are combined in an L-shaped structure, thereby avoiding the influence of differences in processing technology on the conductivity uniformity of the second output element 23.

[0047] like Figure 6 and Figure 7 As shown, the transformer assembly 1 in this embodiment specifically includes an annular magnetic core 101 and a coil 102 wound on the magnetic core 101. A conductive core 103 is disposed through the central hole of the magnetic core 101 along its axial direction. Conductive plates 104 are respectively disposed at both ends of the conductive core 103. The synchronous rectification module 2 is disposed on the left or right side of the magnetic core 101, so that the plane where the synchronous rectification module 2 is located is parallel to the central axis of the conductive core 103, thereby avoiding the synchronous rectification module 2 being located in a region with large magnetic flux and avoiding the influence of eddy currents on the synchronous rectification module 2.

[0048] The conductive core 103 specifically includes a first core 1031 and a second core 1032. The first core 1031 and the second core 1032 are insulated from each other. Specifically, a gap can be provided between the first core 1031 and the second core 1032 to achieve insulation. The gap value is preferably 1mm to 1.5mm. Insulating glue can also be filled in the gap to improve the insulation performance.

[0049] The conductive plate 104 specifically includes a first plate 1041, a second plate 1042, a third plate 1043, and a fourth plate 1044. The two ends of the first battery cell 1031 are electrically connected to the first plate 1041 and the second plate 1042, respectively. The two ends of the second battery cell 1032 are electrically connected to the third plate 1043 and the fourth plate 1044, respectively. The two protrusions 232 of the synchronous rectification module 2 are electrically connected to the first plate 1041 and the fourth plate 1044, respectively. When AC current is applied to the coil 102, the magnetic core 101 will generate alternating magnetic flux, and voltage or current will be induced in the first plate 1041, the second plate 1042, the third plate 1043, and the fourth plate 1044. The first circuit board 1041, the first battery cell 1031 and the second circuit board 1042 are electrically connected in sequence to form a circuit, and the third circuit board 1043, the second battery cell 1032 and the fourth circuit board 1044 are electrically connected in sequence to form another circuit.

[0050] Preferably, in this embodiment, the first board 1041 and the fourth board 1044 are changed from the traditional bent structure to a planar structure, which increases the contact area between the secondary side of the transformer assembly 1 and the first heat sink 6 and the synchronous rectification module 2, thus solving the problem of heat dissipation difficulties on the secondary side of the transformer assembly 1.

[0051] Example 2:

[0052] like Figure 8 and Figure 9As shown, this embodiment provides a water-cooled rectifier power supply, including a chassis 5. A first heat sink 6 and a second heat sink 7 are spaced apart inside the chassis 5. The first heat sink 6 and the second heat sink 7 are preferably made of copper-aluminum composite plates to enhance heat dissipation. A plurality of transformer assemblies 1 are arranged between the first heat sink 6 and the second heat sink 7. In this embodiment, three transformer assemblies 1 are preferably used, spaced apart along the length of the first heat sink 6 and the second heat sink 7. This arrangement allows the required total current to be shared among multiple transformer assemblies 1, achieving current shunting and reducing the heat generated by a single transformer assembly 1, thereby reducing heat loss in the device. Furthermore, the transformer assemblies 1 can be located in different areas of the first heat sink 6 and the second heat sink 7, thus fully utilizing the first heat sink 6 and the second heat sink 7 for timely heat dissipation. This avoids the problem of concentrating current on only one transformer assembly 1, resulting in high heat generation and limited heat dissipation area, preventing timely heat dissipation.

[0053] Preferably, in this embodiment, both the first radiator 6 and the second radiator 7 are provided with channels for coolant to flow through, and the channels of the two can be connected by elbows and pipes, and the pipes are connected out of the chassis 5 to connect to a water source.

[0054] During operation, the transformer assembly 1 and the synchronous rectification module 2 are the main heat sources. In this embodiment, the synchronous rectification module 2 is mounted on the first heat sink 6 and electrically connected to it. The second circuit board 1042 and the third circuit board 1043 are electrically connected to the second heat sink 7, respectively. This separates the transformer assembly 1 and the synchronous rectification module 2, which avoids heat concentration and facilitates the timely dissipation of the heat generated by both through the first heat sink 6 and the second heat sink 7. Furthermore, during disassembly and assembly, the synchronous rectification module 2 and the transformer assembly 1 are less likely to interfere with each other's operating space, thus improving the ease of replacement and maintenance.

[0055] Specifically, a first inductor 8 is mounted on the first heat sink 6, and a second inductor 9 and a current Hall sensor 10 are mounted on the second heat sink 7. One end of the first heat sink 6 extends out of the chassis 5 as one of the output poles, and one end of the second heat sink 7 extends out of the chassis 5 as the other output pole. In this embodiment, the first heat sink 6 and the second heat sink 7 are used as the two output poles of the rectifier power supply, which makes it convenient to directly connect the output poles to the rectifier.

[0056] More specifically, in this embodiment, the second heat sink 7, located away from the first heat sink 6, is also equipped with an input power supply unit 11 and a control system 12. The input power supply unit 11 is used to connect to external current, while the control system 12 is communicatively connected to the drive module 4. Each synchronous rectification module 2 is equipped with a temperature sensor 13, and each temperature sensor 13 is communicatively connected to the control system 12. The temperature sensor 13 sends the real-time monitored temperature information to the control system 12. When the temperature sensor 13 detects abnormal temperature information, the control system 12 will issue a stop or other action command accordingly to prevent the rectifier power supply from burning out. The functions of the above components are all conventional basic functions of a rectifier power supply, which are well known to those skilled in the art and will not be described in detail here.

[0057] It should be stated that the above-described specific embodiments are merely preferred embodiments of this utility model and the technical principles employed. Those skilled in the art should understand that various modifications, equivalent substitutions, and variations can be made to this utility model. However, such variations, as long as they do not depart from the spirit of this utility model, should be within the protection scope of this utility model. Furthermore, some terminology used in this application specification and claims is not limiting, but merely for ease of description.

Claims

1. A transformer structure, characterized by The system includes a transformer assembly (1), a synchronous rectification module (2) is provided on the left or right side of the transformer assembly (1), and the transformer assembly (1) is provided with at least two secondary sides. The synchronous rectification module (2) is electrically connected to the two secondary sides of the transformer assembly (1) respectively. A plurality of absorption modules (3) are provided on the synchronous rectification module (2) through copper pillars. The absorption modules (3) are electrically connected to the synchronous rectification module (2). The synchronous rectification module (2) is also provided with a drive module (4), and the drive module (4) is electrically connected to the synchronous rectification module (2).

2. The transformer structure of claim 1, wherein The synchronous rectification module (2) includes a circuit board (21), a first output element (22) and two second output elements (23). The circuit board (21) is stacked on the first output element (22). The second output elements (23) are symmetrically distributed on both sides of the first output element (22). The first output element (22) has two rows of MOSFETs (24) arranged symmetrically and parallelly. The circuit board (21) has through holes. The MOSFETs (24) pass through the through holes and are electrically connected to the circuit board (21). Each row of MOSFETs (24) is electrically connected to the second output element (23) on the same side.

3. The transformer structure of claim 2, wherein, Each of the second output elements (23) includes a flat plate base (231), and each of the two flat plate bases (231) is provided with a protrusion (232) on the side away from each other, the protrusion (232) being electrically connected to the transformer assembly (1).

4. The transformer structure according to claim 1, characterized in that, The transformer assembly (1) includes an annular magnetic core (101) and a coil (102) wound on the magnetic core (101). A conductive core (103) is provided through the central hole of the magnetic core (101) along its axial direction. Conductive plates (104) are respectively provided at both ends of the conductive core (103). The plane where the synchronous rectification module (2) is located is parallel to the central axis of the conductive core (103).

5. The transformer structure according to claim 4, characterized in that, The conductive core (103) includes a first core (1031) and a second core (1032), wherein the first core (1031) and the second core (1032) are insulated from each other.

6. The transformer structure according to claim 5, characterized in that, The conductive plate (104) includes a first plate (1041), a second plate (1042), a third plate (1043), and a fourth plate (1044). The two ends of the first battery cell (1031) are electrically connected to the first plate (1041) and the second plate (1042), respectively. The two ends of the second battery cell (1032) are electrically connected to the third plate (1043) and the fourth plate (1044), respectively. The two protrusions (232) of the synchronous rectification module (2) are electrically connected to the first plate (1041) and the fourth plate (1044), respectively. The first plate (1041) and the fourth plate (1044) are configured as planar structures.

7. A water-cooled rectifier power supply, comprising the transformer structure of any one of claims 1-6, characterized in that, It also includes a chassis (5), in which a first heat sink (6) and a second heat sink (7) are spaced apart. A plurality of transformer assemblies (1) are arranged between the first heat sink (6) and the second heat sink (7). The transformer assemblies (1) are spaced apart along the length of the first heat sink (6) and the second heat sink (7). The synchronous rectification module (2) is disposed on the first heat sink (6) and electrically connected to it. The second circuit board (1042) and the third circuit board (1043) are electrically connected to the second heat sink (7) respectively.

8. The water-cooled rectifier power supply according to claim 7, characterized in that, The first heat sink (6) is fitted with a first inductor (8), and the second heat sink (7) is fitted with a second inductor (9) and a current Hall sensor (10). One end of the first heat sink (6) extends out of the chassis (5) as one of the output terminals, and one end of the second heat sink (7) extends out of the chassis (5) as the other output terminal.

9. The water-cooled rectifier power supply according to claim 8, characterized in that, The second heat sink (7) is provided with an input power supply unit (11) and a control system (12) on the side away from the first heat sink (6), and the control system (12) is communicatively connected to the drive module (4).

10. The water-cooled rectifier power supply according to claim 9, characterized in that, Each of the synchronous rectification modules (2) is equipped with a temperature sensor (13), which is communicatively connected to the control system (12).

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