Low-loss magnetic integrated transformer

Abstract

The utility model discloses a low loss magnetic integrated transformer relates to magnetic integrated transformer technical field, including casing component and core component, the inside vertical installation of casing component has core component, and the top of casing component is installed with upper cover component, moreover, the bottom of casing component is installed with base component, and the front side upper and lower both ends of casing component are all left and right symmetry horizontal installation has the terminal. This low loss magnetic integrated transformer, through the combination design of casing component, upper cover component, base component and, realized the compactness of structure and the integrity of function, not only provided stable installation environment for internal core component, but also realized reliable fixing and protection to each part of transformer through the upper cover component of its top and the base component of bottom, the setting of core component, further optimized the magnetic flux distribution, reduced the eddy current loss, improved the overall performance of whole transformer.

Description

Technical Field

[0001] This utility model relates to the field of magnetic integrated transformer technology, specifically a low-loss magnetic integrated transformer. Background Technology

[0002] Magnetic integrated transformers are products that combine traditional transformers with magnetic integration technology. By integrating multiple discrete magnetic components (such as inductors and transformers) onto the same magnetic core, they reduce size and weight, while also reducing current ripple and losses and increasing power density.

[0003] To meet the high-capacity requirements of resonant converters, more and more converter design methods employ multiphase transmission technology. However, this leads to problems such as an increase in the number of transformers, increased losses, and reduced power density and efficiency. Magnetic integration technology can effectively solve these problems. Traditional "EE" type magnetic integrated transformers have advantages such as simple structure and ease of design, but they suffer from uneven magnetic flux distribution and high eddy current losses. Utility Model Content

[0004] The purpose of this invention is to provide a low-loss magnetic integrated transformer to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, this utility model provides the following technical solution: a low-loss magnetic integrated transformer, comprising a housing component and a core component. The core component is vertically installed inside the housing component, and a top cover component is installed on the top of the housing component. A base component is installed on the bottom of the housing component, and terminals are symmetrically installed horizontally at both the upper and lower ends of the front side of the housing component. The core component includes a filler, a magnetic core, a wire, and a mating hole. The magnetic core is horizontally inserted in the middle of the filler, and wire is wound around both the upper and lower ends of the magnetic core. The mating holes are symmetrically opened at both the upper and lower ends of the filler.

[0006] Furthermore, the housing component includes an outer shell, an assembly groove, mounting holes, and a protective coating. The assembly groove is provided in the middle of the interior of the outer shell, and horizontal mounting holes are symmetrically provided at both the upper and lower ends of the front side of the outer shell. Moreover, the outer surface of the outer shell is coated with a protective coating.

[0007] Furthermore, the protective coating is applied to the outer surface of the housing using a vacuum impregnation process. The inner surface structure of the assembly groove matches the outer surface structure of the entire core component, and the wiring terminals are horizontally threaded and installed inside the mounting holes.

[0008] Furthermore, the filler is made of a low-hysteresis stretching material to reduce mechanical vibration loss during magnetization, thereby reducing noise and energy loss. The magnetic core is made of PC95 or equivalent material to ensure that the coupling coefficient of the unsaturated transformer is close to 0 throughout the entire operating frequency band. The docking hole is connected to the rear end of the terminal block. The filler is tightly fitted to the inner surface of the assembly slot and the winding is wound around the central column, resulting in a small leakage inductance at the air gap of the transformer, thus ensuring uniform magnetic flux distribution without diffusion at the winding. The magnetic core adopts a "+" shaped structure, and all the windings are wound on the vertical yoke of the "+" shaped magnetic core, with the magnetic flux of the left and right side columns being half of the total magnetic flux.

[0009] Furthermore, the upper cover component includes a protective cover, a buffer plate, a limiting plate, and connecting holes. The top surface of the protective cover is provided with a buffer plate, and the bottom surface of the protective cover is provided with a limiting plate. Connecting holes are provided at the four opposite corners of the protective cover.

[0010] Furthermore, the top surface of the outer shell has holes at four opposite corners that match the connecting hole structure, and the structure of the limiting plate matches the structure of the inner top surface of the assembly groove.

[0011] Furthermore, the base component includes a base, fixing holes, mating grooves, and combination holes. Fixing holes are provided at the four opposite corners of the base, and mating grooves are provided on the top surface of the base. Combination holes are provided at the four opposite corners inside the mating grooves.

[0012] Furthermore, the bottom surface of the outer shell is provided with four opposite corners for assembly holes, and the inner surface structure of the mating groove matches the bottom surface structure of the outer shell.

[0013] This utility model provides a low-loss magnetic integrated transformer, which has the following beneficial effects: 1. This utility model, through the structural design of the core components, uses a low-hysteresis stretching material for the filler, which effectively reduces mechanical vibration losses during magnetization. This not only reduces noise generation but also significantly reduces energy loss. The magnetic core is made of PC95 or equivalent high-quality material, ensuring that the core will not saturate throughout the entire operating frequency band, with the coupling coefficient approaching 0. This significantly improves the efficiency and stability of the transformer. At the same time, the "+" shaped magnetic core design ensures that all windings are wound on the vertical yoke, with the magnetic flux of the two side pillars being half of the total magnetic flux. This layout effectively optimizes the magnetic flux distribution, reduces the diffusion of magnetic flux in the air gap, further reduces leakage inductance, and improves the overall performance of the transformer, thereby minimizing the losses of the entire integrated transformer.

[0014] 2. This utility model, through the design of the shell components, ensures that the assembly groove on the shell body closely matches the outer surface structure of the core component, thereby ensuring the stable installation of the core component inside the shell and reducing additional losses caused by vibration or loosening. At the same time, the protective coating sprayed on the outer surface of the shell body adopts a vacuum impregnation process, which enhances the insulation performance and corrosion resistance of the transformer, effectively extending the service life of the transformer. Furthermore, the horizontal thread of the wiring terminals is installed inside the mounting holes. This installation method is both stable and convenient for wiring operations, improving the practicality and reliability of the transformer.

[0015] 3. This utility model, through the structural arrangement of the upper cover component and the base component, wherein the protective cover in the upper cover component is tightly connected to the hole structure on the top surface of the outer shell through the connecting hole, and the matching of the limiting plate with the inner surface structure of the top of the assembly groove further ensures the fixation of the core component inside the shell. The buffer plate set on the top surface of the protective cover can effectively absorb and disperse external impact force, protecting the internal structure of the transformer from damage. The design of the base component also takes into account stability and practicality. The fixing holes on the base make it easy to fix the transformer in the required position, and the matching of the docking groove with the bottom surface structure of the outer shell ensures the overall stability of the transformer. The setting of the combination hole provides convenience for the installation and disassembly of the transformer.

[0016] 4. In terms of magnetic circuit design, the "+" shaped magnetic core structure combined with the winding method forms a unique magnetic flux path. This path makes the magnetic flux distribution inside the magnetic core more uniform, reducing the risk of magnetic core saturation caused by excessive local magnetic flux density, thereby reducing iron loss. At the same time, since all the windings are wound on the vertical yoke, the distribution of windings on the side posts is reduced, thereby reducing winding losses. This comprehensive magnetic circuit and winding design enables the transformer to achieve a balance between high efficiency and low loss while maintaining a small size.

[0017] 5. In terms of heat dissipation design, this utility model optimizes the layout of the magnetic core and windings, reducing hot spots caused by uneven magnetic flux distribution and dense windings, thus indirectly improving the heat dissipation performance of the transformer. In addition, the tight assembly of the shell components and the setting of the protective coating also help to dissipate heat evenly to a certain extent, preventing local overheating, thereby ensuring the stability and reliability of the transformer under long-term operation. In terms of manufacturing process, the vacuum impregnation process is used to apply the protective coating, which not only improves the adhesion and uniformity of the coating, but also ensures that there are no air bubbles inside the coating, enhancing the insulation strength and moisture resistance of the transformer. At the same time, this process also helps to reduce the impact of the coating on the heat dissipation of the transformer, ensuring the normal operation of the transformer in harsh environments. Attached Figure Description

[0018] Figure 1This is a schematic diagram of the axial side view of the main body of a low-loss magnetic integrated transformer according to this utility model. Figure 2 This is a schematic diagram of the disassembled structure of a low-loss magnetic integrated transformer according to the present invention. Figure 3 This is a three-dimensional structural diagram of the housing component of a low-loss magnetic integrated transformer according to this utility model; Figure 4 This is a three-dimensional structural diagram of the core component of a low-loss magnetic integrated transformer according to this utility model. Figure 5 This is a three-dimensional structural diagram of the upper cover component of a low-loss magnetic integrated transformer according to this utility model. Figure 6 This is a three-dimensional structural diagram of the base component of a low-loss magnetic integrated transformer according to this utility model.

[0019] In the diagram: 1. Shell component; 101. Outer shell; 102. Assembly groove; 103. Mounting hole; 104. Protective coating; 2. Core component; 201. Filler; 202. Magnetic core; 203. Wire wrapped in silk; 204. Connecting hole; 3. Top cover component; 301. Protective cover; 302. Buffer plate; 303. Limiting plate; 304. Connecting hole; 4. Base component; 401. Base; 402. Fixing hole; 403. Connecting groove; 404. Combination hole; 5. Terminal block. Detailed Implementation

[0020] The embodiments of this utility model will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and should not be construed as limiting the scope of this utility model.

[0021] like Figures 1 to 6As shown, a low-loss magnetic integrated transformer includes a housing component 1 and a core component 2. The core component 2 is vertically installed inside the housing component 1, and a top cover component 3 is installed on the top of the housing component 1. A base component 4 is installed on the bottom of the housing component 1, and terminals 5 are symmetrically installed horizontally at both the upper and lower ends of the front side of the housing component 1. The core component 2 includes a filler 201, a magnetic core 202, a wire 203, and mating holes 204. The magnetic core 202 is horizontally inserted in the middle of the filler 201, and the wire 203 is wound around both the upper and lower ends of the magnetic core 202. The mating holes 204 are symmetrically opened at both the upper and lower ends of the filler 201. The filler 201 is made of a low-hysteresis material to reduce mechanical vibration loss during magnetization and reduce noise and energy loss. The core 202 is made of PC95 or equivalent material to ensure that the coupling coefficient of the unsaturated transformer is close to 0 throughout the entire operating frequency band. The mating hole 204 is connected to the rear end of the terminal 5. The filler 201 is tightly fitted to the inner surface of the assembly groove 102 and the winding is wound on the central column, so that the leakage inductance at the air gap of the transformer is small, and the magnetic flux is evenly distributed without diffusion at the winding. The core 202 adopts a "+" shaped structure, and the winding is all wound on the vertical yoke of the "+" shaped core 202, and the magnetic flux of the left and right side columns is half of the total magnetic flux. Through the structural design of the core component 2, the magnetic flux distribution is effectively optimized, the diffusion of magnetic flux at the air gap is reduced, the leakage inductance is further reduced, and the overall performance of the transformer is improved, thereby minimizing the loss of the entire integrated transformer.

[0022] like Figures 1 to 6 As shown, the housing component 1 includes an outer shell 101, an assembly groove 102, mounting holes 103, and a protective coating 104. The assembly groove 102 is provided in the middle of the interior of the outer shell 101, and horizontal mounting holes 103 are symmetrically provided at both the upper and lower ends of the front side of the outer shell 101. The outer surface of the outer shell 101 is coated with a protective coating 104, which is applied to the outer surface of the outer shell 101 using a vacuum impregnation process. The inner surface structure of the assembly groove 102 matches the outer surface structure of the entire core component 2, and the terminal 5 is horizontally threaded into the interior of the mounting hole 103. The assembly groove 102 on the outer shell 101 closely matches the outer surface structure of the core component 2, ensuring the stable installation of the core component 2 inside the housing and reducing additional losses caused by vibration or loosening.

[0023] like Figures 1 to 6As shown, the upper cover component 3 includes a protective cover 301, a buffer plate 302, a limiting plate 303, and connecting holes 304. The top surface of the protective cover 301 is provided with a buffer plate 302, and the bottom surface of the protective cover 301 is provided with a limiting plate 303. Connecting holes 304 are provided at each of the four opposite corners of the protective cover 301. The top surface of the outer shell 101 is provided with holes at each of the four opposite corners that match the structure of the connecting holes 304. The structure of the limiting plate 303 matches the structure of the inner top surface of the assembly groove 102. The base component 4 includes a base 401, a fixing hole 402, a mating groove 403, and a combination hole 404. The base 401... Fixing holes 402 are provided at each of the four diagonal points, and a docking groove 403 is provided on the top surface of the base 401. Combination holes 404 are provided at each of the four diagonal points inside the docking groove 403. Combination holes 404 are provided at each of the four diagonal points on the bottom surface of the outer shell 101. The inner surface structure of the docking groove 403 matches the bottom surface structure of the outer shell 101. The protective cover 301 in the upper cover component 3 is tightly connected to the hole structure on the top surface of the outer shell 101 through the connecting hole 304. With the matching of the limiting plate 303 and the inner surface structure of the top of the assembly groove 102, the fixation of the core component 2 inside the shell is further ensured.

[0024] In summary, as Figures 1 to 6 As shown, when using this low-loss magnetic integrated transformer, first, the transformer is securely installed in the required position through the fixing hole 402 on the base component 4 to ensure that it is in a horizontal and stable state to prevent displacement or damage due to vibration during operation. Next, electrical connections are made using terminal block 5. During the connection process, electrical wiring specifications must be strictly followed to ensure that the wiring is secure and there is no risk of short circuit. The horizontal thread of terminal block 5 is installed inside the mounting hole 103, which makes the wiring operation more convenient and stable. Then, check whether each component of the transformer is installed in place, especially the assembly of the core component 2 and the shell component 1. The filler 201 is tightly attached to the inner surface of the assembly groove 102, which can effectively reduce additional losses and safety hazards caused by poor assembly. Finally, during the operation of the transformer, due to its unique magnetic circuit design, the "+" shaped magnetic core 202 structure combined with the winding method forms a uniform magnetic flux path, reducing the risk of magnetic core 202 saturation caused by excessive local magnetic flux density, thereby reducing iron loss. At the same time, the optimized magnetic core 202 and winding layout also reduces the generation of hot spots and improves heat dissipation performance. Combined with the protective coating 104 sprayed on the outer surface of the shell component 1 using a vacuum impregnation process, the insulation performance and corrosion resistance are enhanced, effectively extending the service life of the transformer and ensuring the stability and reliability of the transformer under long-term operation. The power must be disconnected first during disassembly and maintenance to ensure operational safety and prevent electric shock accidents. Next, following the order from top to bottom, first remove the top cover component 3, loosen the bolt connection between the connecting hole 304 and the hole structure on the top surface of the outer shell 101, and remove the protective cover 301. During the removal process, care should be taken to avoid damage to the buffer plate 302 set on the top surface of the protective cover 301. Then, the core component 2 is removed from the assembly slot 102 of the housing component 1. Since the filler 201 is tightly attached to the inner surface of the assembly slot 102, it must be handled carefully when removing it to prevent damage to the core component 2 or the housing component 1. After removing the core component 2, the inside of the housing component 1 can be cleaned and inspected to ensure that no foreign objects remain. At the same time, the connection of the wiring terminal 5 can be checked. If necessary, the wiring can be rewired or the wiring terminal 5 can be replaced. Next, a detailed inspection of the core component 2 will be carried out, including components such as filler 201, magnetic core 202, wire 203 and mating hole 204. If any damage or wear is found, it should be replaced or repaired in time. If saturation or abnormal coupling coefficient is found in magnetic core 202 during the inspection, magnetic core 202 needs to be replaced to ensure that the transformer is not saturated throughout the entire operating frequency band and that the coupling coefficient is close to 0. At the same time, the base component 4 can be inspected to ensure that the fixing holes 402, docking grooves 403 and combination holes 404 on the base 401 are intact and undamaged. If necessary, they can be repaired or replaced. After maintenance, assemble in the reverse order of disassembly, first installing the core component 2 into the assembly slot 102 of the shell component 1, ensuring that the filler 201 fits tightly against the inner surface of the assembly slot 102. Then install the top cover component 3, and tightly connect the protective cover 301 to the hole structure on the top surface of the outer shell 101 through the connecting hole 304, and ensure that the limiting plate 303 matches the inner surface structure at the top of the assembly groove 102. Finally, the transformer is securely installed in the required position using the fixing holes 402 on the base component 4, and electrical connections and debugging are performed to ensure the transformer operates normally.

[0025] The embodiments of this utility model are given for illustrative and descriptive purposes only, and are not intended to be exhaustive or to limit the utility model to the forms disclosed. Many modifications and variations will be apparent to those skilled in the art. The embodiments were chosen and described in order to better illustrate the principles and practical applications of this utility model, and to enable those skilled in the art to understand this utility model and design various embodiments with various modifications suitable for a particular purpose.

Claims

1. A low-loss magnetic integrated transformer, comprising a housing component (1) and a core component (2), characterized in that: The shell component (1) has a core component (2) installed vertically inside, and a top cover component (3) is installed on the top of the shell component (1). A base component (4) is installed on the bottom of the shell component (1). Terminals (5) are installed horizontally on both the upper and lower ends of the front side of the shell component (1). The core component (2) includes a filler (201), a magnetic core (202), a wire (203), and a docking hole (204). The magnetic core (202) is horizontally inserted in the middle of the filler (201), and the upper and lower ends of the magnetic core (202) are wound with wire (203). The upper and lower ends of the filler (201) are symmetrically provided with docking holes (204).

2. The low-loss magnetic integrated transformer according to claim 1, characterized in that, The shell component (1) includes an outer shell (101), an assembly groove (102), a mounting hole (103), and a protective coating (104). The assembly groove (102) is provided in the middle of the interior of the outer shell (101), and horizontal mounting holes (103) are symmetrically provided at both the upper and lower ends of the front side of the outer shell (101). The outer surface of the outer shell (101) is coated with a protective coating (104).

3. A low-loss magnetic integrated transformer according to claim 2, characterized in that, The protective coating (104) is applied to the outer surface of the outer shell (101) using a vacuum impregnation process. The inner surface structure of the assembly groove (102) matches the outer surface structure of the entire core component (2), and the wiring terminal (5) is horizontally threaded and installed inside the mounting hole (103).

4. A low-loss magnetic integrated transformer according to claim 2, characterized in that, The filler (201) is made of a low hysteresis stretching material to reduce mechanical vibration loss during magnetization, thus reducing noise and energy loss. The magnetic core (202) is made of PC95 or equivalent material to ensure that the coupling coefficient of the unsaturated transformer is close to 0 throughout the entire operating frequency band. The docking hole (204) is connected to the rear end of the terminal (5). The filler (201) fits tightly against the inner surface of the assembly groove (102) and the winding is wound on the central column, so that the leakage inductance at the air gap of the transformer is small, and the magnetic flux is evenly distributed without diffusion at the winding. The magnetic core (202) adopts a "+" shaped structure, and all the windings are wound on the vertical yoke of the "+" shaped magnetic core (202), and the magnetic flux of the left and right side columns is half of the total magnetic flux.

5. A low-loss magnetic integrated transformer according to claim 2, characterized in that, The upper cover component (3) includes a protective cover (301), a buffer plate (302), a limiting plate (303), and a connecting hole (304). The top surface of the protective cover (301) is provided with a buffer plate (302), and the bottom surface of the protective cover (301) is provided with a limiting plate (303). Furthermore, connecting holes (304) are provided at the four opposite corners of the protective cover (301).

6. A low-loss magnetic integrated transformer according to claim 5, characterized in that, The top surface of the outer shell (101) has holes at four opposite corners that match the structure of the connecting hole (304), and the structure of the limiting plate (303) matches the structure of the inner top surface of the assembly groove (102).

7. A low-loss magnetic integrated transformer according to claim 2, characterized in that, The base component (4) includes a base (401), a fixing hole (402), a docking groove (403), and a combination hole (404). The base (401) has fixing holes (402) at four opposite corners, and the base (401) has a docking groove (403) on its top surface. The docking groove (403) has combination holes (404) at four opposite corners inside.

8. A low-loss magnetic integrated transformer according to claim 7, characterized in that, The bottom surface of the outer shell (101) is provided with four opposite corners for the combination hole (404), and the inner surface structure of the docking groove (403) matches the bottom surface structure of the outer shell (101).

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