A transformer structure to improve overall efficiency

Abstract

This utility model relates to the field of transformers and discloses a transformer structure that improves overall efficiency. The structure includes a transformer body, with a first rectifier board body fixedly welded to the front end and a second rectifier board body fixedly welded to the rear end. Both the first and second rectifier board bodies have negative terminal outputs at their bottom ends. A drive circuit and a drive signal input pin are installed on the ends of both the first and second rectifier board bodies furthest from the transformer body. This transformer structure, which improves overall efficiency, directly connects to the output port via the output winding of the transformer's center tap and a large busbar, significantly reducing unnecessary losses caused by excessively long lines or busbars with numerous bends. By integrating the transformer, rectifier board, and busbar into a single unit, it achieves high integration and high density, reducing losses and enabling high-power, high-current output, effectively improving overall efficiency and solving the problems of high losses and low efficiency.

Description

Technical Field

[0001] This utility model relates to the field of transformer technology, specifically a transformer structure that improves overall efficiency. Background Technology

[0002] With the development of technology, people have increasingly higher requirements for the performance of switching power supplies, and the transformer, as one of the core components of a switching power supply, is also facing various challenges. For example, if a customer requires the design of a product with high power, high current, wide voltage range, and high efficiency, then the design of the transformer and its rectifier board structure becomes particularly important.

[0003] In traditional technology, for low- and medium-power switching power supplies, due to their relatively small power and current, transformers are often designed using mature industry techniques to fully meet the load requirements. For example, the primary and secondary windings of the transformer are wound with multi-strand wire or thinner triple-insulated wire. However, for high-power, high-current products, using multi-strand wire winding cannot meet the overcurrent requirements. If multi-strand wire winding is forcibly used to meet the high current requirements, thicker wire is needed to meet the line loss requirements, and winding becomes more difficult, easily causing transformer core breakage. Machine winding is difficult, while manual winding is costly, inefficient, and inconsistent. Using thicker triple-insulated wire wound in parallel for the primary winding and multiple copper sheets wound in parallel for the secondary winding with center taps reduces line loss and is easier to manufacture and install in high-power, high-current products, making it undoubtedly a better choice.

[0004] Furthermore, in traditional technologies, when designing a switching power supply, people often mount the main transformer directly on the main PCB board. This not only occupies excessive PCB board space but also requires repeated desoldering and resoldering of the main PCB board during maintenance, easily increasing the PCB board scrap rate and raising maintenance costs. However, designing the output transformer, rectifier board, and busbars into a single unit not only meets high power density requirements and improves overall efficiency but also facilitates maintenance. If the transformer assembly fails and cannot be repaired, the entire transformer assembly can be replaced, reducing maintenance costs and the scrap rate.

[0005] In summary, how to design a high-power, high-current transformer structure and its rectifier board structure to overcome the shortcomings of the current high-power, high-current, and low-efficiency traditional technologies in the industry is an urgent problem that needs to be solved. Utility Model Content

[0006] The purpose of this utility model is to provide a transformer structure that improves the overall efficiency, so as to solve the problems of high power, high current and low efficiency of traditional technology mentioned in the background art.

[0007] To achieve the above objectives, this utility model provides the following technical solution: a transformer structure for improving overall efficiency, comprising a transformer body, a first rectifier board body fixedly welded to the front end of the transformer body, a second rectifier board body fixedly welded to the rear end of the transformer body, both the first and second rectifier board bodies having a negative terminal output pin at their bottom ends, a drive circuit, a drive signal input pin, a small busbar, an output synchronous rectifier MOS, and an RC absorption circuit mounted on the ends of the first and second rectifier board bodies away from the transformer body, an output filter capacitor fixedly connected to the ends of the first and second rectifier board bodies close to the transformer body, a large busbar mounted on the top of the transformer body, a busbar magnetic core fitted around the large busbar, a transformer primary winding output line extending from the bottom left side of the transformer body, a first rectifier board positive output terminal connection point on the first rectifier board body, and a second rectifier board positive output terminal connection point on each of the second rectifier board bodies.

[0008] As a further technical solution of this utility model, the small busbar is locked with screws at the connection between the positive output terminal of the first rectifier plate and the connection between the positive output terminal of the second rectifier plate.

[0009] As a further technical solution of this utility model, the small busbar and the intermediate tap winding are welded and fixed to form the positive pole of the output voltage.

[0010] As a further technical solution of this utility model, the driving circuit, output synchronous rectification MOS, and RC absorption circuit are installed and fixed to the first rectifier board body and the second rectifier board body through an automatic surface mount structure.

[0011] As a further technical solution of this utility model, the front end of the large busbar is connected to the positive output terminal of the first rectifier plate, and the rear end of the large busbar is connected to the positive output terminal of the second rectifier plate.

[0012] As a further technical solution of this utility model, the first rectifier board body and the second rectifier board body are in a parallel state and are assembled with the transformer body and the large busbar.

[0013] Compared with the prior art, the beneficial effects of this utility model are: the transformer structure that improves the overall efficiency not only realizes the function of improving the overall efficiency and enhancing voltage stability, but also realizes the function of avoiding poor contact and reducing losses;

[0014] (1) By setting up a transformer body, a first rectifier board body, a second rectifier board body, and a large busbar, the PCB boards of the first rectifier board body and the second rectifier board body are made of six-layer boards with 4oz copper thickness. The small loop area is used to reduce the loss on the rectifier board due to the excessive winding of the current loop. The output synchronous rectifier MOS and its driving circuit, RC absorption circuit and output filter capacitor are all placed on the rectifier board. The driving circuit is close to the output synchronous rectifier MOS to reduce the risk of false triggering of MOS conduction caused by stray inductance interference of the driving signal due to the excessive length of the line from the driving circuit to the MOS. The output synchronous MOS is close to the transformer. When the MOS tube is turned on, the large current goes directly to the output port through the output winding of the transformer center tap and the large busbar, which greatly reduces the unnecessary loss caused by the excessive length of the line or the excessive length and bending of the busbar. By combining the transformer, rectifier board and busbar into one unit, the high integration and high density reduce the loss and realize the output of high power and high current, which effectively improves the efficiency of the whole machine.

[0015] (2) By setting up an output synchronous rectifier MOS, an RC snubber circuit, and an output filter capacitor, the RCD snubber circuit is close to the output synchronous rectifier MOS to absorb the spike signal in time, reducing the risk of the MOS being broken down. The output filter capacitor is close to the MOS and forms a Π-shaped filter with the output busbar with the magnetic core to filter out the high-frequency signal caused by the MOS switching, thereby reducing the ripple of the output voltage and providing a stable and clean voltage for the electrical equipment.

[0016] (3) By setting the primary winding output of the transformer, the primary winding output of the transformer adopts a three-layer insulated wire three-winding parallel connection method, and the secondary adopts a middle tap multiple copper sheet parallel connection method; the primary winding and the secondary winding adopt a cross installation method, the secondary copper sheet is wrapped with high temperature insulating tape, the primary and secondary windings are insulated and isolated with epoxy gaskets, and the primary and secondary winding outputs are fixed with epoxy boards to avoid the outputs being crooked, affecting assembly, causing poor contact, resulting in high loss and low efficiency. Attached Figure Description

[0017] Figure 1 This is a frontal three-dimensional structural diagram of the present invention;

[0018] Figure 2 This is a bottom view of the structure of this utility model;

[0019] Figure 3 This is a side view of the structure of this utility model;

[0020] Figure 4 This is a front view structural diagram of the present invention.

[0021] In the diagram: 1. Transformer primary winding output; 2. Rectifier board negative terminal; 3. Drive circuit; 4. Drive signal input terminal; 5. Small busbar; 6. Output synchronous rectifier MOS; 7. RC snubber circuit; 8. Connection point of the positive output terminal of the second rectifier board; 9. Output filter capacitor; 10. Large busbar; 11. Busbar core; 12. Transformer body; 13. Connection point of the positive output terminal of the first rectifier board; 14. Main body of the first rectifier board; 15. Main body of the second rectifier board. Detailed Implementation

[0022] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0023] Please see Figure 1-4 This utility model provides an embodiment of a transformer structure for improving overall efficiency, comprising a transformer body 12, a first rectifier plate body 14 fixedly welded to the front end of the transformer body 12, and a second rectifier plate body 15 fixedly welded to the rear end of the transformer body 12. Both the first rectifier plate body 14 and the second rectifier plate body 15 have a negative terminal output pin 2 at their bottom ends. A drive circuit 3, a drive signal input pin 4, a small busbar 5, and an output pin are installed on the ends of the first rectifier plate body 14 and the second rectifier plate body 15 furthest from the transformer body 12. The transformer body 12 includes a rectifier MOS 6, an RC snubber circuit 7, an output filter capacitor 9 fixedly connected to one end of the first rectifier board body 14 and the second rectifier board body 15 near the transformer body 12, a large busbar 10 installed at the top of the transformer body 12, a busbar core 11 fitted outside the large busbar 10, a transformer primary winding output line 1 extending from the bottom left side of the transformer body 12, a first rectifier board positive output terminal connection 13 provided on the first rectifier board body 14, and a second rectifier board positive output terminal connection 8 provided on both the second rectifier board body 15.

[0024] The first rectifier board body 14 and the second rectifier board body 15 are parallel to each other and are assembled with the transformer body 12 and the large busbar 10.

[0025] Specifically, such as Figure 1 and Figure 2As shown, the PCB boards of the first rectifier board body 14 and the second rectifier board body 15 are six-layer boards with 4oz copper thickness. They adopt a small loop area to reduce the loss on the rectifier board caused by excessive current loop winding. The output synchronous rectifier MOS6 and its drive circuit 3, RC snubber circuit 7 and output filter capacitor 9 are all placed on the rectifier board. The drive circuit 3 is close to the output synchronous rectifier MOS6 to reduce the risk of stray inductance interference from the drive signal caused by excessively long lines from the drive circuit 3 to the MOS, which may cause false triggering of the MOS to conduct. The output synchronous rectifier MOS6 is close to the transformer. When the MOS is turned on, the large current goes directly to the output port through the output winding of the transformer center tap and the large bus bar 10, which greatly reduces unnecessary losses caused by excessively long lines or excessively long bus bars with many bends. By combining the transformer, rectifier board and bus bar into one unit, the high integration and high density reduce losses and realize high power and high current output, effectively improving the overall efficiency of the machine.

[0026] The small busbar 5 is locked with screws at the connection point 13 of the positive output terminal of the first rectifier board and the connection point 8 of the positive output terminal of the second rectifier board. The small busbar 5 and the intermediate tap winding are welded and fixed to form the positive terminal of the output voltage.

[0027] Specifically, such as Figure 1 and Figure 4 As shown, the primary winding output line 1 of the transformer adopts a three-layer insulated wire and three windings connected in parallel, while the secondary winding adopts a multi-copper sheet connected in parallel with a center tap. The primary and secondary windings are installed in a cross manner. The secondary copper sheets are wrapped with high-temperature insulating tape. Epoxy gaskets are used for insulation and isolation between the primary and secondary windings. The primary and secondary winding outputs are fixed with epoxy boards to prevent the outputs from being misaligned, affecting assembly, causing poor contact, resulting in high losses and low efficiency.

[0028] The drive circuit 3, output synchronous rectifier MOS 6, and RC snubber circuit 7 are installed and fixed to the first rectifier board body 14 and the second rectifier board body 15 through an automatic surface mount structure. The front end of the large busbar 10 is connected to the positive output terminal 13 of the first rectifier board, and the rear end of the large busbar 10 is connected to the positive output terminal 8 of the second rectifier board.

[0029] Specifically, such as Figure 1 and Figure 3 As shown, the RC absorption circuit 7 is close to the output synchronous rectifier MOS 6 to absorb the spike signal in time, reducing the risk of MOS breakdown. The output filter capacitor 9 is close to the MOS and forms a Π-shaped filter with the output bus bar with the magnetic core, which filters out the high-frequency signal caused by the MOS switching, thereby reducing the ripple of the output voltage and providing a stable and clean voltage for the electrical equipment.

[0030] Working principle: The rectifier board PCB uses a six-layer board. First, the surface mount device driver circuit 3, output synchronous rectifier MOS 6, and RC snubber circuit 7 are placed using automated surface mount equipment. Then, the output filter capacitor 9 is inserted into the rectifier board. At the same time, the assembly holes of the transformer and busbar on the rectifier board are plugged with high-temperature resistant liquid adhesive. Then, it is reflowed through an automated wave soldering machine. After reflowing, the adhesive used to plug the holes is cleaned off. The next step is to reflow the transformer, busbar, and rectifier board components. After the large busbar 10 returns, it is first sent to the magnetic core manufacturer for magnetic bonding between the busbar and the core. After processing and manufacturing the core 11, the small busbar 5 is first screwed onto the designated position on the rectifier board where the output filter capacitor 9 has been attached and inserted. Next, the transformer body 12, the large busbar 10 and the rectifier board are assembled using a jig and then wave soldered and reflowed. The primary winding output 1 of the transformer adopts a three-winding parallel connection, and the secondary adopts a multi-copper-sheet parallel connection with a center tap. By combining the transformer, rectifier board and busbar into one unit, high integration and high density are achieved, reducing losses and realizing high power and high current output, effectively improving the overall efficiency.

[0031] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A transformer structure for improving overall efficiency, comprising a transformer body (12), characterized in that: The front end of the transformer body (12) is fixedly welded with a first rectifier board body (14), and the rear end of the transformer body (12) is fixedly welded with a second rectifier board body (15). The bottom ends of both the first rectifier board body (14) and the second rectifier board body (15) are provided with rectifier board negative terminal pins (2). A drive circuit (3), a drive signal input pin (4), a small busbar (5), an output synchronous rectifier MOS (6), and an RC absorption circuit (7) are installed on the end of both the first rectifier board body (14) and the second rectifier board body (15) away from the transformer body (12). The main body of the rectifier plate (14) and the main body of the second rectifier plate (15) are fixedly connected to the end of the transformer body (12). A large bus bar (10) is installed at the top of the transformer body (12). A bus bar magnetic core (11) is fitted on the outside of the large bus bar (10). The transformer primary winding output line (1) extends from the bottom left side of the transformer body (12). The first rectifier plate main body (14) is provided with a first rectifier plate positive output terminal connection (13). The second rectifier plate main body (15) is provided with a second rectifier plate positive output terminal connection (8).

2. The transformer structure for improving overall efficiency according to claim 1, characterized in that: The small busbar (5) is screwed to the connection point (13) of the positive output terminal of the first rectifier plate and the connection point (8) of the positive output terminal of the second rectifier plate.

3. The transformer structure for improving overall efficiency according to claim 1, characterized in that: The small busbar (5) and the intermediate tap winding are welded and fixed to form the positive pole of the output voltage.

4. The transformer structure for improving overall efficiency according to claim 1, characterized in that: The drive circuit (3), output synchronous rectifier MOS (6), and RC absorption circuit (7) are installed and fixed to the first rectifier board body (14) and the second rectifier board body (15) through an automatic patch structure.

5. The transformer structure for improving overall efficiency according to claim 1, characterized in that: The front end of the large busbar (10) is connected to the positive output terminal (13) of the first rectifier plate, and the rear end of the large busbar (10) is connected to the positive output terminal (8) of the second rectifier plate.

6. The transformer structure for improving overall efficiency according to claim 1, characterized in that: The first rectifier board body (14) and the second rectifier board body (15) are parallel to each other and are assembled with the transformer body (12) and the large busbar (10).

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