A charging module winding assembly

Abstract

This utility model discloses a charging module winding assembly, including: a magnetic core assembly, a base plate, and a winding assembly. The magnetic core assembly includes a first magnetic core portion and a second magnetic core portion, which are connected. A first air duct is formed at the junction of the first and second magnetic core portions, and a second and a third air duct are formed away from the junction. The magnetic core assembly also has a receiving cavity, and the winding assembly is located in the receiving cavity. The winding assembly includes a magnetic block, and the axial surface of the magnetic block has a plurality of first ventilation holes and a plurality of second ventilation holes. The winding assembly also includes a first coil, a second coil, and a third coil, which are wound on the magnetic block. The magnetic core assembly is fixedly connected to the base plate, and a current equalization ring magnetic ring is provided above the base plate. The base plate has a first through hole, a second through hole, a third through hole, and a fourth through hole. By combining segmented air gaps and setting multiple ventilation holes and air ducts, the heat dissipation efficiency is improved.

Description

Technical Field

[0001] This utility model relates to the field of charging device technology, and in particular to a charging module winding assembly. Background Technology

[0002] With the continuous development of the new energy vehicle industry, the market demand for electric vehicles is steadily increasing, and charging modules, one of their core components, are rapidly iterating towards higher power density. Under this trend, the internal winding components of the module face a key challenge: limited by the overall size of the charging module, the winding components need to bear higher power, leading to a continuous increase in their own size and a corresponding increase in wire diameter. Therefore, within the limited installation space of the charging module, how to design winding components that can effectively reduce heat generation and enhance heat dissipation performance has become a core requirement that the industry urgently needs to address.

[0003] Patent No. CN114649134A describes a transformer for a new energy charging pile. It adopts a structure of a housing, a magnetic core assembly, and a winding assembly. The housing is provided with heat dissipation holes and ventilation openings, combined with an exhaust fan to improve heat dissipation. The magnetic core assembly and the coil assembly are fixed on the base plate for easy installation and maintenance. Although heat dissipation holes and an exhaust fan are provided on the housing, the magnetic core and the winding assembly still lack an effective ventilation and heat dissipation structure, making it difficult for the heat generated by the coil to be quickly conducted and dissipated.

[0004] However, in the process of realizing this utility model, the inventors discovered that the above-mentioned technology has at least the following technical problems:

[0005] 1. Because the gaps between the winding coils of the charging module are small or even non-existent, it leads to problems with ventilation and heat dissipation.

[0006] 2. Due to the limited space in the charging module, there is a problem of insufficient number of ventilation openings and low heat dissipation efficiency. Summary of the Invention

[0007] The purpose of this utility model is to provide a charging module winding assembly to solve the technical problems of poor ventilation and heat dissipation, insufficient number of ventilation openings and low heat dissipation efficiency in the prior art. It achieves the technical effect of improving heat dissipation performance and increasing heat dissipation capacity per unit area without taking up extra space.

[0008] To address the aforementioned technical problems, this utility model provides a charging module winding assembly, aiming to construct an efficient heat dissipation channel by optimizing its internal structure. The assembly includes:

[0009] A magnetic core assembly forms a receiving cavity. The magnetic core assembly includes a first magnetic core portion and a second magnetic core portion connected to each other. In order to guide airflow, a first air duct is formed at the junction of the first magnetic core portion and the second magnetic core portion, and a second air duct and a third air duct are respectively formed at positions away from the junction.

[0010] A winding assembly is disposed within the accommodating cavity of the magnetic core assembly. The winding assembly includes a magnetic block, the axial surface of which is provided with a plurality of first ventilation holes and a plurality of second ventilation holes. Crucially, the first, second, and third air channels on the magnetic core assembly, together with the first and second ventilation holes on the magnetic block, form a three-dimensional heat dissipation channel, capable of efficiently dissipating heat. The winding assembly also includes a first coil, a second coil, and a third coil respectively wound on the magnetic block.

[0011] The magnetic core assembly is fixedly connected to the base plate via it. For ease of electrical connection, the base plate has a first through hole, a second through hole, a third through hole, and a fourth through hole.

[0012] A current-equalizing magnetic ring is disposed above the base plate to achieve current equalization in the secondary winding.

[0013] Through the above technical solution, this utility model integrates the heat dissipation structure with the component body to form an internal self-circulating heat dissipation network, effectively solving the heat dissipation problem caused by the compact structure in the prior art.

[0014] As a preferred embodiment, the first magnetic core portion and the second magnetic core portion are connected by thermally conductive adhesive;

[0015] As a preferred embodiment, the magnetic block includes a first magnetic block, a second magnetic block, and a third magnetic block;

[0016] As a preferred embodiment, a first epoxy plate is provided between the first magnetic block and the second magnetic block, and a second epoxy plate is provided between the second magnetic block and the third magnetic block. By providing epoxy plates between the magnetic blocks, the coil gap is increased.

[0017] As a preferred embodiment, the magnetic block is cylindrical in shape;

[0018] As a preferred embodiment, the diameter of the magnetic block is greater than the minimum distance of the magnetic core assembly perpendicular to its axis.

[0019] As a preferred embodiment, the current-equalizing ring is disposed above the base plate to achieve current equalization in the secondary winding. For electrical connection, the current-equalizing ring may be provided with a first connection pin, a second connection pin, a third connection pin, and a fourth connection pin, which correspond one-to-one with the first through hole, the second through hole, the third through hole, and the fourth through hole opened on the base plate.

[0020] By creating air ducts at different locations on the magnetic core assembly, combined with ventilation holes on the magnetic blocks and perforations on the base plate, a complete heat dissipation system is formed, enabling rapid heat conduction and dissipation. For secondary dual-winding or multi-winding outputs, a current sharing mechanism needs to be integrated. Current sharing rings need to be fitted onto the opposite terminals (pins 3 and 4, or pins 5 and 6) of the secondary winding N2 (secondary winding) or N3 (tertiary winding) to facilitate current sharing between the two secondary windings.

[0021] One or more technical solutions provided in this utility model have at least the following technical effects or advantages:

[0022] 1. Because the magnetic core assembly of this utility model has a first air duct, a second air duct and a third air duct, and the axial surface of the magnetic block of the winding assembly has a number of first ventilation holes and second ventilation holes, and the air ducts and ventilation holes together form a three-dimensional heat dissipation channel, the air circulation path inside the assembly is effectively improved, and the technical problem of poor ventilation and heat dissipation caused by small winding gap and lack of internal heat dissipation structure in the prior art is solved, thereby significantly improving the heat dissipation performance of the entire assembly.

[0023] 2. Because this solution constructs a heat dissipation system by cleverly setting air ducts and ventilation holes in the structure of the magnetic core assembly and the magnetic block itself, it can significantly increase the heat dissipation surface area and ventilation volume without increasing the external volume of the components or occupying the limited installation space of the charging module. This solves the technical problems of insufficient number of ventilation holes and low heat dissipation efficiency caused by space constraints in the prior art, thereby achieving the technical effect of improving the heat dissipation capacity per unit area. Attached Figure Description

[0024] To more clearly illustrate the embodiments of this utility model, the accompanying drawings used in the description of the embodiments will be briefly introduced below.

[0025] Figure 1 This is a side view of the charging module winding assembly provided in an embodiment of the present utility model;

[0026] Figure 2 yes Figure 1 A front view of the magnetic core assembly shown;

[0027] Figure 3 This is another side view of the charging module winding assembly provided in this embodiment of the utility model;

[0028] Figure 4 yes Figure 1 An exploded side view of the magnetic core assembly shown.

[0029] Figure 5 yes Figure 1 An exploded front view of the magnetic core assembly shown;

[0030] Figure 6 This is a three-dimensional structural schematic diagram of the winding assembly in an embodiment of this utility model;

[0031] Figure 7 This is a three-dimensional structural schematic diagram of the charging module winding assembly provided in an embodiment of the present utility model;

[0032] Figure 8 yes Figure 6 End view of the winding assembly shown;

[0033] Figure 9 yes Figure 6 A three-dimensional structural diagram of the winding assembly shown from another angle.

[0034] In the attached diagram: 1. Magnetic core assembly; 101. First magnetic core section; 102. Second magnetic core section; 201. First air duct; 202. Second air duct; 203. Third air duct; 3. Winding assembly; 4. Magnetic block; 401. First magnetic block; 402. Second magnetic block; 403. Third magnetic block; 501. First ventilation hole; 502. Second ventilation hole; 6. Base plate; 7. Current equalization ring magnetic ring; 801. First epoxy board; 802. Second epoxy board; 901. First through hole; 902. Second through hole; 903. Third through hole; 904. Fourth through hole; 10. First wiring pin; 11. First coil; 12. Second coil; 13. Third coil; 14. Second wiring pin; 15. Fourth air duct; 16. Fifth air duct Detailed Implementation

[0035] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, in the description of this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0036] Please see Figures 1 to 6 This utility model provides a charging module winding assembly, which aims to solve the problem of poor heat dissipation in existing high-power winding assemblies. The winding assembly mainly includes a base plate 6 as a mounting base, a magnetic core assembly 1 mounted on the base plate 6, a winding assembly 3 housed inside the magnetic core assembly 1, and a current-equalizing ring magnetic ring 7 for current equalization.

[0037] like Figure 2As shown, the magnetic core assembly 1 includes a first magnetic core portion 101 and a second magnetic core portion 102. Both the first and second magnetic core portions 101 and 102 are made of ferrite material; however, other soft magnetic materials well-known in the art, such as amorphous or nanocrystalline alloys, can also be used. The first magnetic core portion 101 and the second magnetic core portion 102 are connected by thermally conductive adhesive. The thermal conductivity of the adhesive is 1.0-3.0 W / (m·K), allowing the heat generated by the coil and magnetic core during operation to be transferred away more quickly, indirectly improving the overall heat dissipation efficiency. Simultaneously, in addition to using thermally conductive adhesive, the fixed components can also be connected using other fixing methods with good thermal conductivity, such as using mechanical fasteners in conjunction with thermally conductive silicone pads for fixation and heat conduction. A first air duct 201 is provided at the junction of the first magnetic core 101 and the second magnetic core 102. A second air duct 202 and a third air duct 203 are provided on the other side of the first magnetic core 101 and the second magnetic core 102, respectively, away from the junction of the first magnetic core 101 and the second magnetic core 102. The second air duct 202 and the third air duct 203 are parallel and symmetrical.

[0038] like Figure 1 , Figure 6 , Figure 8 As shown, the winding assembly 3 includes a magnetic block 4. The axial surface of the magnetic block has a plurality of first ventilation holes 501 and a plurality of second ventilation holes 502. In this embodiment, the diameters of the first ventilation holes 501 and second ventilation holes 502 are 3-8 mm, and the number of first ventilation holes 501 and second ventilation holes 502 is 6-12. The first ventilation holes 501 and second ventilation holes 502 are axially aligned to form a straight ventilation channel, allowing air to flow directly from one end of the magnetic block to the other. However, those skilled in the art will understand that the diameter and number of ventilation holes are not limited to this and can be adjusted according to specific power density, heat dissipation requirements, and structural strength. For example, fewer but larger diameter ventilation holes or more but smaller diameter ventilation holes can be provided, as long as effective airflow can be achieved.

[0039] like Figure 7 , Figure 8 , Figure 9As shown, the winding assembly 3 further includes a first coil 11, a second coil 12, and a third coil 13. The first coil 11, second coil 12, and third coil 13 are respectively wound around the magnetic block 4, which has several ventilation openings. The magnetic block 4 includes a first magnetic block 401, a second magnetic block 402, and a third magnetic block 403. Epoxy boards are provided between adjacent magnetic blocks. A first epoxy board 801 is provided between the first magnetic block 401 and the second magnetic block 402, and a second epoxy board 802 is provided between the second magnetic block 402 and the third magnetic block 403. The thickness of the first epoxy board 801 and the second epoxy board 802 is 0.5-2 mm, which solves the problem of poor ventilation and heat dissipation. The magnetic block 4 is cylindrical in shape. Specifically, the cylindrical shape of the magnetic block 4 facilitates the winding of the coil. Since the diameter of the magnetic block 4 is larger than the internal width of the magnetic core assembly 1, a fourth air duct 15 and a fifth air duct 16 are formed on both sides between the outer circumference of the magnetic block 4 and the inner wall of the magnetic core assembly 1. These two air ducts, together with the first air duct 201, the second air duct 202, and the third air duct 203, constitute a three-dimensional heat dissipation channel network. In this embodiment, the diameter of the magnetic block 4 is 50 mm, and the minimum distance between the magnetic core assembly 1 and the magnetic core assembly 1 in the direction perpendicular to the axis is 45 mm, so that the magnetic block 4 protrudes from the magnetic core assembly 1, forming the fourth air duct 15 and the fifth air duct 16. By setting up multiple ventilation openings and air ducts, the problem of limited space and low heat dissipation efficiency of the charging module is solved, and the heat dissipation capacity per unit area is improved without taking up additional space. In other embodiments, as long as the design principle of the magnetic block diameter being greater than the internal width of the magnetic core is maintained, any combination of sizes that can form an effective airflow channel, such as a diameter difference between 1mm and 10mm, falls within the protection scope of this utility model.

[0040] like Figure 7The base plate 6 serves as the mounting foundation for the entire winding assembly. The magnetic core assembly 1 is fixedly connected to the base plate 6 by bolts or other fastening methods. A current-equalizing ring 7 is disposed above the base plate 6. To achieve electrical connection with an external circuit board, the base plate 6 has multiple through holes, specifically a first through hole 901, a second through hole 902, a third through hole 903, and a fourth through hole 904 in this embodiment. The current-equalizing ring 7 is used to achieve current balancing when multiple secondary windings are output. To achieve this function and complete the electrical connection, the current-equalizing ring 7 is provided with multiple connection pins. Specifically, the current-equalizing ring 7 has a first connection pin 10, which passes through and communicates with the first through hole 901 to lead to an external circuit. The current-equalizing ring 7 also has a second connection pin 14, which passes through and communicates with the second through hole 902. Similarly, the current-equalizing ring 7 is also provided with a third and a fourth connection pin, which pass through and are connected to the third through hole 903 and the fourth through hole 904 respectively. With this design, the opposite ends of the secondary winding can first be fitted with the current-equalizing ring 7, and then connected to the through holes on the base plate 6 through their respective connection pins, thereby achieving electrical lead-out while effectively ensuring that the current of two or more secondary windings can be evenly distributed.

[0041] When this invention is in operation, the first, second, and third coils 11, 12, and 13 generate heat when energized. This heat is dissipated primarily through two paths. Path 1: Internal convection cooling. External cooling airflow (e.g., driven by a fan) enters from the second air duct 202 and third air duct 203 at one end of the magnetic core assembly 1, and from the first ventilation hole 501 and second ventilation hole 502 on the end face of the magnetic block 4. The airflow passes through the ventilation channel inside the magnetic block and flows through the fourth air duct 15 and fifth air duct 16 formed between the outer periphery of the magnetic block and the inner wall of the magnetic core, directly carrying away the heat generated by the coils and the magnetic block, and finally exiting from the first air duct 201 and the corresponding ventilation hole at the other end, forming efficient internal convection cooling. Path 2: Conduction-convection cooling. Some heat is conducted through the thermally conductive adhesive to the first magnetic core 101 and the second magnetic core 102, and then carried away by the external airflow flowing through the first air duct 201, second air duct 202, and third air duct 203. Through this three-dimensional heat dissipation network design that combines internal ventilation holes with external air ducts, heat can be quickly and dissipated to the external environment through multiple paths, thereby significantly improving the heat dissipation efficiency of the entire component.

[0042] Although preferred embodiments of the present invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the present invention.

[0043] Obviously, those skilled in the art can make various modifications and variations to this utility model without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this utility model and their equivalents, this utility model also intends to include these modifications and variations.

Claims

1. A charging module winding assembly, characterized in that, include: A magnetic core assembly (1) includes a first magnetic core portion (101) and a second magnetic core portion (102). The first magnetic core portion (101) is connected to the second magnetic core portion (102). A first air duct (201) is provided at the junction of the first magnetic core portion (101) and the second magnetic core portion (102). A second air duct (202) and a third air duct (203) are provided at positions away from the junction of the first magnetic core portion (101) and the second magnetic core portion (102). The magnetic core assembly (1) forms an accommodating cavity. The winding assembly (3) is located in the accommodating cavity. The winding assembly (3) includes a magnetic block (4). The axial surface of the magnetic block is provided with a plurality of first ventilation holes (501) and a plurality of second ventilation holes (502). The first air duct (201), the second air duct (202), and the third air duct (203) are interconnected with the first ventilation holes (501) and the second ventilation holes (502) to form a heat dissipation channel that allows cooling airflow to pass through the interior and surface of the winding assembly. The winding assembly (3) also includes a first coil (11), a second coil (12), and a third coil (13). The first coil (11), the second coil (12), and the third coil (13) are respectively wound on the magnetic block (4). The base plate (6) is fixedly connected to the magnetic core assembly (1). The base plate (6) has a first through hole (901), a second through hole (902), a third through hole (903), and a fourth through hole (904). A flow equalization ring magnetic ring (7) is disposed above the base plate (6).

2. The charging module winding assembly as described in claim 1, characterized in that, The first magnetic core (101) and the second magnetic core (102) are connected by thermally conductive adhesive.

3. A charging module winding assembly as described in claim 1, characterized in that, The magnetic block (4) includes a first magnetic block (401), a second magnetic block (402), and a third magnetic block (403).

4. A charging module winding assembly as described in claim 3, characterized in that, A first epoxy plate (801) is disposed between the first magnetic block (401) and the second magnetic block (402), and a second epoxy plate (802) is disposed between the second magnetic block (402) and the third magnetic block (403).

5. A charging module winding assembly as described in claim 1, characterized in that, The magnetic block (4) is cylindrical in shape.

6. A charging module winding assembly as described in claim 5, characterized in that, The diameter of the magnetic block (4) is greater than the minimum distance between the magnetic core assembly (1) and its axis.

7. A charging module winding assembly as described in claim 1, characterized in that, The current equalization ring magnetic ring (7) is provided with a first wiring pin (10) and a second wiring pin (14). The first wiring pin (10) is connected to the first through hole (901), and the second wiring pin (14) is connected to the second through hole (902).

8. A charging module winding assembly as described in claim 1, characterized in that, The current equalization ring magnetic ring (7) is provided with a third connection pin and a fourth connection pin. The third connection pin is connected to the third through hole (903), and the fourth connection pin is connected to the fourth through hole (904).

9. A charging module winding assembly as described in claim 1, characterized in that, Each of the first ventilation hole (501) and the second ventilation hole (502) is aligned axially to form a through ventilation channel.

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