A deep integration multi-winding transformer with controllable leakage inductance

Abstract

The utility model relates to a kind of leakage inductance controllable depth integrated multi-winding transformer, including first magnetic core, second magnetic core and multiple windings, first magnetic core and second magnetic core are equipped with first magnetic column, common magnetic column and second magnetic column, first magnetic core and second magnetic core abut, to make the gap between common magnetic column;Winding is wound on first magnetic core and second magnetic core, and there is different winding between the incomplete coupling formed, and the width of gap is controlled between different windings by adjusting leakage inductance.The utility model is formed by two windings between the incomplete coupling, its leakage inductance acts as resonance inductance in power converter, without additional design separate inductance, realize inductance and transformer depth integration, only need to combine single-stage isolation AC-DC power supply topology framework can realize core magnetic component four-in-one effect, that is, it has PFC rectification function and isolation voltage and current regulating function simultaneously, effectively reduce component quantity, loss, volume and cost, and improve conversion efficiency.

Description

Technical Field

[0001] This utility model relates to the field of transformer technology, and more specifically, to a deeply integrated multi-winding transformer with controllable leakage inductance. Background Technology

[0002] With the increasing demand for energy conservation, emission reduction, and air pollution control, new energy storage systems, new energy engineering vehicles, and electric vehicles have been widely promoted and applied in the market. Existing technology uses a two-stage circuit conversion to manage battery charging and discharging or supply power to loads. First, the AC mains power is rectified by a PFC (Power Factor Correction) circuit, and then voltage and current are regulated using an isolated DC-DC converter circuit. The core magnetic components include four parts: a PFC inductor, an OBC (On-Board Charger) resonant inductor, an OBC main transformer, and a DC-DC main transformer. This technology suffers from drawbacks such as a large number of components, high losses, large size, high cost, and low conversion efficiency. Utility Model Content

[0003] The technical problem to be solved by this utility model is that the number of components is large, the loss is large, the size is large, the cost is high and the conversion efficiency is low. In view of the above-mentioned defects of the prior art, a deeply integrated multi-winding transformer with controllable leakage inductance is provided.

[0004] The technical solution adopted by this utility model to solve its technical problem is: A deeply integrated multi-winding transformer with controllable leakage inductance is constructed, comprising a base and a first magnetic core, a second magnetic core, and multiple windings mounted on the base. Both the first and second magnetic cores have a first magnetic post, a common magnetic post, and a second magnetic post. A first groove is formed between the first magnetic post and the common magnetic post, and a second groove is formed between the second magnetic post and the common magnetic post. The first and second magnetic posts are at the same horizontal height, and are higher than the common magnetic post in the horizontal direction. The first and second magnetic cores abut against each other, such that two first grooves form a first through-hole, two second grooves form a second through-hole, and a gap is formed between the two common magnetic posts, with the gap connecting the first and second through-holes. The windings are wound on the first and second magnetic cores, and different windings form incomplete coupling. The leakage inductance between different windings is controlled by adjusting the width of the gap.

[0005] Furthermore, the area of ​​the cross-section of the first magnetic post is not less than the area of ​​the cross-section of the second magnetic post.

[0006] Furthermore, the width of the gap is adjusted by setting the height of the shared magnetic post.

[0007] Furthermore, the gap may be empty or filled with a third magnetic core. When the gap is filled with the third magnetic core, the permeability of the third magnetic core is much lower than that of the first magnetic core and the second magnetic core.

[0008] Furthermore, the number of windings is two or three, and the material is a coil or a conductive sheet.

[0009] Furthermore, when the winding includes two windings, the windings include a first winding and a second winding, and both are coils, a portion of the coil of the first winding is wound in the first groove of the first magnetic core and the second magnetic core, and the remaining coil of the first winding and all the coils of the second winding are wound in a cross-winding manner in the second groove of the first magnetic core and the second magnetic core, so that the first winding and the second winding form an incomplete coupling.

[0010] Furthermore, when the winding includes three windings, the winding also includes a third winding, and the third winding uses a conductive sheet, which is wound around the second groove of the first magnetic core and the second magnetic core, and covers the second winding, so that the third winding is fully coupled to the second winding.

[0011] Furthermore, the conductive sheet contains multiple turns of coil and does not contain an intermediate shaft end.

[0012] Furthermore, the conductive sheet may have multiple third through holes or no holes, and the size and shape of the third through holes are not fixed.

[0013] Furthermore, the first winding, the second winding, and the third winding are not wound on the common magnetic post.

[0014] The beneficial effects of this utility model are as follows: This invention utilizes the incomplete coupling between two windings, with the leakage inductance acting as the resonant inductor in the power converter. This eliminates the need for a separate inductor design, achieving deep integration of the inductor and transformer. Combined with a single-stage isolated AC-DC power supply topology, it achieves the effect of combining four core magnetic components (PFC inductor, OBC resonant inductor, OBC main transformer, and DC-DC main transformer) into one. This means it simultaneously possesses PFC rectification and isolation voltage and current regulation functions, effectively reducing product size and weight, minimizing raw material usage, and consequently reducing component losses. This not only improves the converter's conversion efficiency but also saves costs. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the utility model will be further described below in conjunction with the accompanying drawings and embodiments. The drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Figure 1 This is a perspective view of a deeply integrated multi-winding transformer with controllable leakage inductance, comprising two windings, according to one embodiment of this utility model. Figure 2 This is a perspective view of a deeply integrated multi-winding transformer with controllable leakage inductance, comprising three windings, according to one embodiment of this utility model. Figure 3 This is a top view of the first magnetic core in one embodiment of the present invention; Figure 4 This is a perspective view of the first magnetic core in one embodiment of the present invention; Figure 5 This is a perspective view of the first and second magnetic cores assembled in one embodiment of this utility model; Figure 6 This is a perspective view of a third magnetic core filling the gap in one embodiment of this utility model; Figure 7 This is a magnetic simulation waveform diagram of a deeply integrated multi-winding transformer with controllable leakage inductance in one embodiment of this utility model. Figure 8 This is a flux loop diagram of a deeply integrated multi-winding transformer with controllable leakage inductance in one embodiment of this utility model. Figure 9 This is an equivalent schematic diagram of a deeply integrated multi-winding transformer with controllable leakage inductance, comprising two windings with leakage inductance, according to one embodiment of the present invention. Figure 10 This is an equivalent schematic diagram of a deeply integrated multi-winding transformer with controllable leakage inductance, comprising two windings with leakage inductance, according to one embodiment of the present invention. Figure 11 This is a perspective view of a third winding with a third through hole in one embodiment of the present invention.

[0016] Labeling Explanation: 1. Base; 2. First magnetic core; 3. Second magnetic core; 4. First winding; 5. Second winding; 6. Third winding; 7. First magnetic flux loop; 8. Second magnetic flux loop; 9. Third magnetic flux loop; 231. First magnetic post; 232. First groove; 233. Common magnetic post; 234. Second groove; 235. Second magnetic post; 236. First through hole; 237. Second through hole; 238. Gap; 239. Third groove; 2311. Cross-section of first magnetic post; 2351. Cross-section of second magnetic post; 2381. Third magnetic core; 41. Part of the first winding coil; 42. Remaining coil of the first winding; 45. Leakage inductance; 51. All coils of the second winding; 61. Third through hole. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0018] Please refer to the attached document. Figures 1-11 This invention proposes a deeply integrated multi-winding transformer with controllable leakage inductance, including a base 1 and a first magnetic core 2, a second magnetic core 3, and multiple windings mounted on the base 1. Both the first magnetic core 2 and the second magnetic core 3 are provided with a first magnetic post 231, a common magnetic post 233, and a second magnetic post 235. A first groove 232 is formed between the first magnetic post 231 and the common magnetic post 233, and a second groove 234 is formed between the second magnetic post 235 and the common magnetic post 233. The first magnetic post 231 and the second magnetic post 235 are at the same height in the horizontal direction. The first magnetic core 2 and the second magnetic core 3 abut against each other, so that the two first grooves 232 form a first through hole 236, the two second grooves 234 form a second through hole 237, and a gap 238 is formed between the two common magnetic cores 233, and the gap 238 conducts the first through hole 236 and the second through hole 237; the winding is wound on the first magnetic core 2 and the second magnetic core 3, and there are different windings forming incomplete coupling, and the leakage inductance between different windings is controlled by adjusting the width of the gap 238.

[0019] In this embodiment, a deeply integrated multi-winding transformer with controllable leakage inductance includes a first magnetic core 2, a second magnetic core 3, and multiple windings. Both the first magnetic core 2 and the second magnetic core 3 are provided with a first magnetic post 231, a common magnetic post 233, and a second magnetic post 235. A first groove 232 is formed between the first magnetic post 231 and the common magnetic post 233, and a second groove 234 is formed between the second magnetic post 235 and the common magnetic post 233. The first magnetic post 231 and the second magnetic post 235 are at the same height in the horizontal direction and are higher than the common magnetic post 233 in the horizontal direction. The first magnetic core 2 and the second magnetic core 3 abut against each other so that the two first grooves 232 form a first through hole 236, the two second grooves 234 form a second through hole 237, and a gap 238 is formed between the two common magnetic posts 233. The gap 238 conducts through the first through hole 236 and the second through hole 237. When there are two windings, the transformer is a two-winding transformer; when there are three windings, the transformer is a three-winding transformer. Both include a first winding 4 and a second winding 5. The coil 41 of the first winding is wound in the first groove 232 of the first magnetic core 2 and the second magnetic core 3. The remaining coil 42 of the first winding and all the coils 51 of the second winding are wound in the second groove 234 of the first magnetic core 2 and the second magnetic core 3 in a cross-winding manner, so that the first winding 4 and the second winding 5 form an incomplete coupling. The leakage inductance between the first winding 4 and the second winding 5 can be precisely adjusted by adjusting the size of the gap 238.

[0020] This invention utilizes the leakage inductance 45 between the first winding 4 and the second winding 5 of a transformer to serve as the resonant inductor in a power converter. This eliminates the need for a separate inductor design, as well as additional copper wire and magnetic core materials. This not only reduces product size and weight, but also decreases raw material usage, thereby reducing component losses and improving converter efficiency, while also saving costs. Furthermore, by combining this invention with a single-stage isolated AC-DC power supply topology, four magnetic components (PFC inductor, OBC resonant inductor, OBC main transformer, and DC-DC main transformer) from traditional technologies can be deeply integrated, achieving a four-in-one effect. This means it simultaneously possesses PFC rectification and isolation voltage and current regulation functions, effectively improving the problems of numerous and varied components, high component losses, large size, high cost, and low conversion efficiency in traditional technologies.

[0021] Please refer to Figures 3-7 The leakage inductance between different windings is controlled by adjusting the width of the gap 238, which is adjusted by setting the height of the common magnetic column 233. The gap 238 can be empty or filled with the third magnetic core 2381. When the gap 238 is filled with the third magnetic core 2381, the permeability of the third magnetic core 2381 is much lower than that of the first magnetic core 2 and the second magnetic core 3.

[0022] In specific implementation: both the first magnetic core 2 and the second magnetic core 3 are provided with a first magnetic post 231, a common magnetic post 233 and a second magnetic post 235, and a first groove 232 is formed between the first magnetic post 231 and the common magnetic post 233, and a second groove 234 is formed between the second magnetic post 235 and the common magnetic post 233; the first magnetic post 231 and the second magnetic post 235 are at the same height in the horizontal direction and are higher than the common magnetic post 233 in the horizontal direction. When the first magnetic core 2 and the second magnetic core 3 abut, the two first magnetic posts 231 abut against each other, and the two first grooves 232 form a first through hole 236. The two second magnetic posts 235 abut against each other, and the two second grooves 234 form a second through hole 237. A gap 238 is formed between the two common magnetic posts 233, and the gap 238 conducts through the first through hole 236 and the second through hole 237. The width of the gap 238 can be adjusted by adjusting the height of the common magnetic post 233.

[0023] Furthermore, the windings are respectively wound around the sidewalls of the first through hole 236 and the second through hole 237, such as... Figure 7 The figure shows a magnetic simulation waveform of a deeply integrated multi-winding transformer with controllable leakage inductance. As can be seen from the figure, the magnetic flux of the winding wound in the first through hole 236 is large. Part of the leakage flux of the first through hole 236 is transmitted to the winding wound in the second through hole 237 through the common magnetic post 233. The amount of leakage flux transmitted is negatively correlated with the width of the gap 238. The larger the width of the gap 238, the smaller the amount of leakage flux transmitted. That is, the leakage inductance between different windings can be controlled by adjusting the width of the gap 238.

[0024] Furthermore, gap 238 can also be optionally filled with one or more third magnetic cores 2381, such as... Figure 6 The image shows a three-dimensional view of the gap 238 filled with a third magnetic core 2381. The permeability of the third magnetic core 2381 is much lower than that of the first magnetic core 2 and the second magnetic core 3. The leakage inductance is adjusted by using the third magnetic core 2381 with lower permeability, which can generate the desired leakage inductance and prevent the magnetic field from dispersing around the gap 238.

[0025] Please refer to Figures 1-8 The area of ​​the cross-section 2311 of the first magnetic column is not less than the area of ​​the cross-section 2351 of the second magnetic column.

[0026] In practical implementation: such as Figure 8 The diagram shows the flux loop of a deeply integrated multi-winding transformer with controllable leakage inductance. The windings form three flux loops on the first core 2 and the second core 3, namely, flux loop 7, flux loop 8, and flux loop 9. Flux loop 7 surrounds the first through-hole 236, flux loop 8 surrounds the second through-hole 237, and flux loop 9 surrounds the entire first core 2 and the second core 3. Figure 7The figure shows a magnetic simulation waveform of a deeply integrated multi-winding transformer with controllable leakage inductance. As can be seen from the figure, the magnetic flux of the first magnetic flux circuit 7 is much greater than that of the second magnetic flux circuit 8. Therefore, the area of ​​the cross-section 2311 of the first magnetic column is not less than the area of ​​the cross-section 2351 of the second magnetic column, in order to reduce the magnetic flux density in the first magnetic flux circuit 7 and reduce the heat generation of the magnetic devices.

[0027] Please refer to Figures 1-9 When the winding includes two windings, the windings include a first winding 4 and a second winding 5, and both are coils, the first winding part of the coil 41 is wound in the first groove 232 of the first magnetic core 2 and the second magnetic core 3, and the remaining coil 42 of the first winding and all the coils 51 of the second winding are wound in a cross-winding manner in the second groove 234 of the first magnetic core 2 and the second magnetic core 3, so that the first winding 4 and the second winding 5 form an incomplete coupling.

[0028] In practical implementation: When the winding includes two windings, the transformer of this utility model is a dual-winding transformer. In this case, the windings include a first winding 4 and a second winding 5, both made of coil material. In one specific embodiment, the coils can be made of copper wire. Part of the first winding coil 41 is wound in the first groove 232 of the first magnetic core 2 and the second magnetic core 3, and the remaining coil 42 of the first winding and all the coils 51 of the second winding are wound in a cross-winding manner in the second groove 234 of the first magnetic core 2 and the second magnetic core 3, so that the first winding 4 and the second winding 5 form an incomplete coupling. Figure 9 The diagram shown is an equivalent schematic of a two-winding transformer with leakage inductance 45. The first winding 4 and the second winding 5 are not fully coupled, and there is a certain amount of leakage inductance 45. In this embodiment, the leakage inductance is 8uH (microhenries).

[0029] Furthermore, a third groove 239 is provided on the opposite side of the second groove 234 in the first magnetic core 2 and the second magnetic core 3. At this time, the shared magnetic post 233, the second groove 234, the third groove 239 and the second magnetic post 235 in the first magnetic core 2 and the second magnetic core 3 form an H-shaped structure, which is convenient for coil winding and not easy to fall off. Similarly, a groove can also be provided on the opposite side of the first groove 232 to facilitate coil winding, without restriction.

[0030] Please refer to Figures 1-10 When the winding includes three windings, the winding also includes a third winding 6, and the third winding 6 uses a conductive sheet. The conductive sheet is wound around the second groove 234 of the first magnetic core 2 and the second magnetic core 3, and covers the second winding 5 so that the third winding 6 and the second winding 5 are well coupled. In specific implementation: When the winding includes three windings, the transformer of this utility model is a three-winding transformer. In this case, the windings include a first winding 4, a second winding 5, and a third winding 6. The first winding 4 and the second winding 5 are made of coil material and are wound in the same way as a two-winding transformer. The third winding 6 is made of conductive sheet material. In one specific embodiment, the conductive sheet is made of copper. The conductive sheet is wound around the second groove 234 of the first magnetic core 2 and the second magnetic core 3, respectively, and covers the second winding 5 in a wrapping manner to ensure good coupling between the third winding 6 and the second winding 5. In this embodiment, the third winding 6 uses two copper sheets with a gate-shaped structure. The width of the first end of the copper sheet is half the inner diameter of the second through hole 237. The first ends of the two copper sheets are placed adjacently inside the second through hole 237, and the second ends are located on the sides of the first magnetic core 2 and the second magnetic core 3, respectively, and are both inserted into the base 1 to facilitate electrical connection.

[0031] Furthermore, such as Figure 10 The diagram shown is an equivalent schematic of a three-winding transformer with leakage inductance 45. The first winding 4 and the second winding 5 are not fully coupled, and there is a certain amount of leakage inductance 45. In this embodiment, the leakage inductance is 8uH (microhenries). The second winding 5 and the third winding 6 are well coupled.

[0032] Please refer to Figures 1-11 The conductive sheet contains multiple turns of coil and does not contain an intermediate shaft head; the conductive sheet may have multiple third through holes 61, and the size and shape of the third through holes 61 are not fixed.

[0033] In specific implementation: the conductive sheet contains multiple turns of coil, and the conductive sheet only includes the ports at both ends, with no port in the middle, that is, it does not contain an intermediate shaft head; the conductive sheet may not have any holes, or it may have multiple third through holes 61. The third through holes 61 facilitate the penetration of thermally conductive adhesive, so as to better dissipate heat from the first winding portion coil 41 and the second winding 5 coil wrapped in the third winding 6.

[0034] Furthermore, such as Figure 11 The figure shown is a perspective view of the third winding 6 with a third through hole 61. The size and shape of the third through hole 61 are not limited. In a specific embodiment, the shape of the third through hole 61 is not limited to regular square, circle, hexagon and rhombus, etc., but can also be other irregular shapes.

[0035] Please refer to Figures 1-7 The first winding 4, the second winding 5, and the third winding 6 are not wound on the common magnetic post 233.

[0036] The coils of the first winding 4, the second winding 5, and the third winding 6 are not wound on the common magnetic post 233 where the gap 238 is located, so that the coils of the first winding 4, the second winding 5, and the third winding 6 are connected in parallel with the common magnetic post 233 where the gap 238 is located, which helps to ensure the smooth flow of magnetic flux loop in the main magnetic circuit.

[0037] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, apparatus, article, or method that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, apparatus, article, or method. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, apparatus, article, or method that includes that element.

[0038] The above description is only a preferred embodiment of this application and does not limit the patent scope of this application. Any equivalent structural or procedural changes made based on the content of this application's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this application.

Claims

1. A deeply integrated multi-winding transformer with controllable leakage inductance, comprising a base, characterized in that, It also includes a first magnetic core, a second magnetic core and multiple windings mounted on a base. The first magnetic core and the second magnetic core are each provided with a first magnetic post, a common magnetic post and a second magnetic post, and a first groove is formed between the first magnetic post and the common magnetic post, and a second groove is formed between the second magnetic post and the common magnetic post. The first magnetic post and the second magnetic post are at the same height in the horizontal direction, and are higher than the height of the common magnetic post in the horizontal direction; the first magnetic core and the second magnetic core abut each other so that the two first grooves form a first through hole, the two second grooves form a second through hole, and a gap is formed between the two common magnetic posts, and the gap conducts through the first through hole and the second through hole; the winding is wound on the first magnetic core and the second magnetic core, and there is incomplete coupling between different windings, and the leakage inductance between different windings is controlled by adjusting the width of the gap.

2. The deeply integrated multi-winding transformer with controllable leakage inductance according to claim 1, characterized in that, The cross-sectional area of ​​the first magnetic post is not less than the cross-sectional area of ​​the second magnetic post.

3. The deeply integrated multi-winding transformer with controllable leakage inductance according to claim 1, characterized in that, The width of the gap is adjusted by setting the height of the shared magnetic post.

4. The deeply integrated multi-winding transformer with controllable leakage inductance according to claim 3, characterized in that, The gap may be empty or filled with the third magnetic core. When the gap is filled with the third magnetic core, the permeability of the third magnetic core is much lower than that of the first magnetic core and the second magnetic core.

5. The deeply integrated multi-winding transformer with controllable leakage inductance according to claim 1, characterized in that, The number of windings is two or three, and the material is a coil or a conductive sheet.

6. The deeply integrated multi-winding transformer with controllable leakage inductance according to claim 5, characterized in that, When the winding includes two windings, the windings include a first winding and a second winding, and both are coils, a portion of the coils of the first winding are wound in the first groove of the first magnetic core and the second magnetic core, and the remaining coils of the first winding and all the coils of the second winding are wound in a cross-winding manner in the second groove of the first magnetic core and the second magnetic core, so that the first winding and the second winding form an incomplete coupling.

7. The deeply integrated multi-winding transformer with controllable leakage inductance according to claim 6, characterized in that, When the winding includes three windings, the winding also includes a third winding, and the third winding uses a conductive sheet. The conductive sheet is wound around the second groove of the first magnetic core and the second magnetic core, and covers the second winding, so that the third winding is fully coupled to the second winding.

8. The deeply integrated multi-winding transformer with controllable leakage inductance according to claim 7, characterized in that, The conductive sheet contains multiple turns of coil and does not contain an intermediate shaft.

9. The deeply integrated multi-winding transformer with controllable leakage inductance according to claim 7, characterized in that, The conductive sheet may or may not have multiple third through holes, and the size and shape of the third through holes are not fixed.

10. The deeply integrated multi-winding transformer with controllable leakage inductance according to claim 7, characterized in that, The first winding, the second winding, and the third winding are not wound on the common magnetic post.

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