CN114244073A - Voltage-expanding toroidal transformer and magnetic integration structure and method of voltage-expanding toroidal transformer and resonant converter - Google Patents

Voltage-expanding toroidal transformer and magnetic integration structure and method of voltage-expanding toroidal transformer and resonant converter Download PDF

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Publication number
CN114244073A
CN114244073A CN202111557109.1A CN202111557109A CN114244073A CN 114244073 A CN114244073 A CN 114244073A CN 202111557109 A CN202111557109 A CN 202111557109A CN 114244073 A CN114244073 A CN 114244073A
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China
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group
winding
primary windings
primary
voltage
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CN202111557109.1A
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CN114244073B (en
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姚建华
张文学
张乐乐
闫志强
刘月华
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Beijing Dynamic Power Co Ltd
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Beijing Dynamic Power Co Ltd
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/29—Terminals; Tapping arrangements for signal inductances
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H01F41/076—Forming taps or terminals while winding, e.g. by wrapping or soldering the wire onto pins, or by directly forming terminals from the wire
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M3/00—Conversion of dc power input into dc power output
    • H02M3/22—Conversion of dc power input into dc power output with intermediate conversion into ac
    • H02M3/24—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters
    • H02M3/28—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac
    • H02M3/325—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal
    • H02M3/335—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M3/3353—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only having at least two simultaneously operating switches on the input side, e.g. "double forward" or "double (switched) flyback" converter
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B70/00—Technologies for an efficient end-user side electric power management and consumption
    • Y02B70/10—Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Coils Or Transformers For Communication (AREA)
  • Coils Of Transformers For General Uses (AREA)

Abstract

The application provides a voltage-expanding toroidal transformer and a magnetic integration structure and method of the voltage-expanding toroidal transformer and a resonant converter, belongs to the technical field of magnetic integration, and is used for solving the problem of poor voltage resistance of a magnetic integration technology in the related technology. The annular transformer comprises an annular magnetic core, at least two groups of primary windings with the same coil turns, at least one secondary winding and at least two groups of connecting terminals; all the primary windings in one group of primary windings are cascaded end to end, and all the primary windings are uniformly wound on the annular magnetic core; each group of connecting terminals is provided with at least one pair, each pair of connecting terminals in each group is connected with all homonymous terminals of a corresponding group of primary windings one by one, the other connecting terminals are connected with all synonym terminals of the group of primary windings, and the secondary windings are wound on the annular magnetic core. The toroidal transformer is capable of voltage spreading. The magnetic integration method is used for realizing the magnetic integration structure. The magnetic integrated structure comprises the toroidal transformer, and the magnetic integrated structure and the method also have the effect of voltage spreading.

Description

Voltage-expanding toroidal transformer and magnetic integration structure and method of voltage-expanding toroidal transformer and resonant converter
Technical Field
The application relates to the technical field of magnetic integration, in particular to a voltage-spreading toroidal transformer and a magnetic integration structure and method of the voltage-spreading toroidal transformer and a resonant converter.
Background
The magnetic integration technology is to wind two or more discrete devices in the converter, such as inductors, transformers and the like, on a pair of magnetic cores and structurally concentrate the discrete devices together so as to reduce the volume and the weight of the magnetic devices in the power module, reduce current ripples, reduce the loss of the magnetic devices and improve the dynamic performance of the power module, and the magnetic integration technology has important significance for improving the performance and the power density of the power module.
With the increase of the power requirement of the power supply module, the power supply module is required to have stronger voltage withstanding performance, and higher requirements are also provided for the voltage withstanding performance of the magnetic integration technology.
Disclosure of Invention
The application provides a voltage-expanding toroidal transformer, a magnetic integration structure of the voltage-expanding toroidal transformer and a resonant converter, and a method of the voltage-expanding toroidal transformer and the magnetic integration structure.
In a first aspect, the present application provides a step-up voltage toroidal transformer. The structure includes: the transformer comprises an annular magnetic core, at least two groups of primary windings, at least one secondary winding and at least two groups of connecting terminals;
the number of turns of the primary winding is the same; each group of primary windings comprises at least one primary winding, and the number of the primary windings in different groups of primary windings is the same; all the primary windings are uniformly distributed and wound on the annular magnetic core, and when one group of primary windings comprises more than one primary winding, the same group of primary windings are connected in series in a head-to-tail cascade mode;
one of the pair of connecting terminals is connected with all homonymous ends of the corresponding group of primary windings, and the other connecting terminal is connected with all heteronymous ends of the corresponding group of primary windings;
and all the secondary windings are wound on the annular magnetic core.
By adopting the technical scheme, when the annular transformer is applied, a plurality of groups of H-bridge switching circuits which are connected in series can be respectively connected with a plurality of pairs of connecting terminals, the control on the direction of exciting current in the primary winding can be realized through the H-bridge switching circuits, the fact that the magnetic flux in the annular magnetic core is annular is guaranteed, the using effect is equal to the fact that all the primary windings are connected in series under the driving voltage, the driving voltage can be uniformly distributed to the H-bridge switching circuits, the connecting terminals and the exciting coils, and under the condition that the voltage resistance of each H-bridge switching circuit, the connecting terminals and the primary windings is equal, the annular transformer can bear higher voltage, namely has better voltage resistance.
Furthermore, the whole annular magnetic core is an annular or rectangular ring formed by integral molding or splicing.
Furthermore, distributed air gaps are symmetrically arranged on the annular magnetic core.
Furthermore, the primary winding and the secondary winding are formed by winding multiple strands.
Further, the secondary winding and the corresponding resonant inductor are formed by winding a multi-strand wire.
The shell is provided with a first accommodating groove, and the annular magnetic core wound with the primary winding and the secondary winding is arranged in the first accommodating groove by adopting a vacuum encapsulation process.
The primary winding is connected with the connecting terminal through the switching branch circuit.
In a second aspect, the present application provides a magnetic integrated structure of a voltage-spreading toroidal transformer and a resonant converter, the structure comprising: the toroidal transformer according to any of the above first aspects, further comprising: the resonant inductors correspond to the secondary windings of the annular transformer one by one;
one end of the resonance inductor is connected with one end of the corresponding resonance inductor.
Further, the resonance inductor is formed by non-continuous winding at one end of the corresponding secondary winding.
Further, the casing of the toroidal transformer is further provided with a second accommodating groove, and the resonant inductor is arranged in the second accommodating groove by adopting a vacuum encapsulation process.
In a third aspect, the present application provides a method of magnetically integrating a voltage-spreading toroidal transformer with a resonant converter. The method comprises the following steps:
at least two groups of pins are uniformly arranged on the annular magnetic core, the number of the pins of each group is equal, and at least two pins are arranged in each group;
relative to each group of pins, uniformly winding a primary winding with the same number of turns of coils between every two adjacent pins, and when one group of primary windings comprises more than one primary windings, cascading the primary windings in the primary windings end to end;
winding at least one secondary winding on the annular magnetic core;
vacuum encapsulating an annular magnetic core wound with a primary winding and a secondary winding in a shell, and leading out one end of the pin and two ends of the secondary winding;
aiming at each secondary winding, a leading-out end is connected with a resonant inductor;
welding and connecting one end of the pin lead-out by adopting a circuit board which is pre-configured with a connecting terminal and a switching shunt circuit so as to enable the connecting terminal to be connected with the pin; and one of the pair of connecting terminals in each group of connecting terminals is connected with the homonymous terminals of all the primary windings in the corresponding group through the switching shunt and the pins, and the other connecting terminal is connected with the heteronymous terminals of all the primary windings in the group through the switching shunt and the pins.
Furthermore, the primary winding, the secondary winding and the resonant inductor are wound by multiple strands.
Further, the resonance inductor connected with the secondary winding is formed by winding one leading-out end of the secondary winding without breaking wires.
In summary, the present application at least includes the following beneficial effects:
1. the toroidal transformer capable of improving the voltage resistance of a power module and the magnetic integration structure and method of the toroidal transformer and the resonant converter are provided;
2. the primary winding, the secondary winding and the resonant inductor are wound by adopting multiple strands of wires, so that the uniformity of exciting current is improved, and the loss of proximity effect and eddy current loss are reduced;
3. adopt secondary winding to draw forth end and do not break the line winding resonance inductance, do not have the great solder joint of sectional area between the secondary winding that makes the winding of stranded line form and the resonance inductance, can avoid the loss of the effect of closing on because of the solder joint produces, also can avoid the solder joint that probably leads to generate heat and even a series of problems such as fusing, be favorable to further promoting power module's performance, prolong power module's life.
It should be understood that what is described in this summary section is not intended to limit key or critical features of the embodiments of the application, nor is it intended to limit the scope of the application. Other features of the present application will become apparent from the following description.
Drawings
The above and other features, advantages and aspects of various embodiments of the present application will become more apparent by referring to the following detailed description when taken in conjunction with the accompanying drawings. In the drawings, like or similar reference characters designate like or similar elements, and wherein:
fig. 1 is a schematic structural diagram illustrating an overall structure of a magnetic integrated structure of a voltage-spreading toroidal transformer and a resonant converter in a first embodiment of the present application;
fig. 2 is an exploded schematic view of a magnetic integrated structure of a voltage-spreading toroidal transformer and a resonant converter in a first embodiment of the present application;
FIG. 3 is a schematic structural diagram of a toroidal core according to a first embodiment of the present application;
fig. 4 shows a partially enlarged view of a portion a in fig. 2;
fig. 5 is a schematic structural diagram illustrating a resonant inductor and a toroidal core wound with a primary winding and a secondary winding according to an embodiment of the present application mounted in a housing;
fig. 6 is an electrical schematic diagram illustrating a magnetic integrated structure of a voltage-spreading toroidal transformer and a resonant converter in the first embodiment of the present application;
fig. 7 is a schematic diagram showing an electrical structure of a control circuit corresponding to a magnetic integrated structure of a voltage-spreading toroidal transformer and a resonant converter in the first embodiment of the present application.
Description of reference numerals: 1. an annular magnetic core; 11. distributing air gaps; 2. a primary winding; 21. a pin; 211. a connecting plate; 212. connecting grooves; 22. mounting a plate; 4. a resonant inductor; 5. a housing; 51. a first accommodating groove; 52. a second accommodating groove; 6. a circuit board; 61. a yielding groove; 62. and a connection terminal.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are some embodiments of the present application, but not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.
In addition, the term "and/or" herein is only one kind of association relationship describing an associated object, and means that there may be three kinds of relationships, for example, a and/or B, which may mean: a exists alone, A and B exist simultaneously, and B exists alone. In addition, the character "/" herein generally indicates that the former and latter related objects are in an "or" relationship.
The application provides a magnetic integration structure and a magnetic integration method of a voltage-spreading toroidal transformer and a resonant converter, and the technologies are applied to a power module and can improve the voltage resistance of the power module.
In a first aspect, the embodiment of the application discloses a magnetic integration structure of a voltage-spreading toroidal transformer and a resonant converter.
The first embodiment is as follows:
referring to fig. 1 and 2, the present embodiment discloses a magnetic integrated structure of a voltage-spreading toroidal transformer and a resonant converter, which includes a toroidal core 1, two sets of primary windings 2, three secondary windings, and three resonant inductors 4.
Referring to fig. 2 and 3, the annular magnetic core 1 is a circular ring, and is specifically formed by splicing two half circular magnetic cores, and an epoxy plate is arranged at the splicing position of the two half circular magnetic cores, so that two symmetrically distributed air gaps 11 are formed on the annular magnetic core 1. The existence of the distributed air gap 11 is beneficial to the magnetic flux balance of the primary winding 2 which is wound subsequently.
In this embodiment, the material of the annular magnetic core 1 may be manganese-zinc power ferrite, and the thickness of the epoxy plate may be 0.6 mm.
Two groups of round edges are uniformly distributed in a melting way and wound on the annular magnetic core 1, a group of pins 21 are arranged relative to each group of primary windings 2, each primary winding 2 is positioned between two pins 21, and a group of primary windings 2 are cascaded end to end through the pins 21. In this embodiment, there are five primary windings 2 in each group, there are six pins 21 in each group, and twelve pins 21 in total are circularly and symmetrically distributed in the annular magnetic core 1 in two groups, the six pins 21 close to each other are in one group, the other six pins 21 close to each other are in another group, and five primary windings 2 in one group are respectively arranged at five intervals between the six pins 21 in one group.
Referring to fig. 2 and 4, in order to facilitate the installation and fixation of the twelve pins 21, a circular mounting plate 22 adapted to the overall shape of the annular magnetic core 1 is disposed in advance, and the twelve pins 21 are uniformly and circularly symmetrically distributed and fixed on a plate surface of the mounting plate 22 with the center of the circle of the circular mounting plate 22 as the axis. Each pin 21 includes a connecting plate 211 and two connecting grooves 212, the two connecting grooves 212 are specifically configured on two plate surfaces at one end of the connecting plate 211, and the connecting grooves 212 are integrally U-shaped, and specifically can be configured and molded by an L-shaped plate and the plate surface of the connecting plate 211. When pin 21 is fixed to mounting panel 22, connecting plate 211 stands on the face of mounting panel 22, and the notch of connecting groove 212 deviates from the face of mounting panel 22.
In actual installation, the pins 21 can be installed by arranging the installation plate 22 on one end face of the annular magnetic core 1, and twelve equivalent division slots can be formed between the connection plates 211 of the twelve pins 21, which is beneficial to subsequent winding of the primary winding 2 and the secondary winding.
In order to increase the uniformity of the primary winding 2, reduce the proximity effect and improve the coupling effect of the primary winding 2 and the secondary winding, the primary winding 2 is wound by adopting multiple strands. For one group of the pins 21, each primary winding 2 is wound between two adjacent pins 21, and two ends of each primary winding 2 are respectively led into two connecting grooves 212 opposite to the two adjacent pins 21 and are respectively connected with the connecting grooves 212 in a welding manner. The winding directions of the adjacent primary windings 2 are opposite, so that the adjacent primary windings 2 are connected through two homonymous terminals or two heteronymous terminals, that is, a group of five primary windings 2 are cascaded end to end through a group of six pins 21. Of the twelve pins 21, the pins 21 used for the homonymous terminal connection and the pins 21 used for the synonym terminal connection are distributed at intervals. In the present embodiment, the leads 21 are made of copper and are integrally formed.
Referring to fig. 1 and 2, the three secondary windings are respectively wound around the annular magnetic core 1 (not shown in the figure) and are uniformly distributed on the annular magnetic core 1, and the winding directions of the three secondary windings are the same. In the present embodiment, since the connection plates 211 of the pins 21 can also perform the dividing function, the connection plates 211 of the twelve pins 21 form twelve dividing slots on the annular magnetic core 1, so that each of the three secondary windings is uniformly wound in four dividing slots. Similarly, in order to increase the uniformity of the secondary winding, reduce the proximity effect and improve the coupling effect of the secondary winding and the primary winding 2, the secondary winding is wound by multiple strands. In addition, in order to facilitate subsequent connection and configuration, two ends of each secondary winding are led out, and stranded wires with certain lengths are reserved at each end according to requirements.
In this embodiment, the number of turns of the coil of the primary winding 2 is two, and the number of turns of the coil of the secondary winding is twenty, although the specific number of turns of the coil of the primary winding 2 and the secondary winding can be specifically determined according to the requirement of the transformation ratio and the specification of the stranded wire and the annular magnetic core 1.
The three resonant inductors 4 are arranged in one-to-one correspondence with the three secondary windings, and the three resonant inductors 4 are respectively connected to the homonymous ends of the three secondary windings. Similarly, to increase the uniformity of the resonant inductor 4 and reduce the proximity effect, the resonant inductor 4 is also wound by multiple strands. In addition, because the resonant inductor 4 and the secondary winding are both stranded wires, and the secondary winding needs to be connected with the resonant inductor 4, in order to eliminate a connection point between the secondary winding and the resonant inductor 4 and avoid a strong proximity effect of the connection point with a large cross section area, in this embodiment, the resonant inductor 4 is specifically formed by continuously winding the stranded wires led out from the same-name end of the secondary winding, so as to form a structure in which the secondary winding and the resonant inductor 4 are integrally connected in series. Two ends of the structure of the secondary winding connected in series with the resonant inductor 4 are respectively led out and respectively provided with an OT terminal.
In the above, the magnetic integration of the resonant inductor 4 in the resonant converter and the primary coil 2 and the secondary coil in the toroidal transformer is realized, and since the application does not relate to the improvement of other parts of the resonant converter, no description is made on other parts of the resonant converter.
Referring to fig. 2 and 5, the magnetic integrated structure further includes a case 5, and after the winding of the primary winding 2 and the secondary winding on the annular magnetic core 1 is completed, the annular magnetic core 1 wound with the primary winding 2 and the secondary winding may be disposed in the case 5; after the winding operation of the resonant inductor 4 is completed, the wound resonant inductor 4 may be disposed in the case 5.
To achieve magnetic integration, the case 5 is integrally formed in a shape formed by combining a cylindrical portion and a rectangular solid portion, specifically, the cylindrical portion and the rectangular solid portion have the same height, the diameter of the cylindrical portion is the same as the length of the rectangular solid portion, and both ends of the cylindrical portion and both ends of the rectangular solid portion in the direction of the height are flush with each other. The cylindrical portion of the housing 5 is open at one end to form a cylindrical first accommodation groove 51 coaxial with the cylindrical portion, and the rectangular parallelepiped portion of the housing 5 is open at one end and partitioned by two partitions to form three rectangular parallelepiped second accommodation grooves 52 arranged along the length of the rectangular parallelepiped portion. The first receiving groove 51 and the second receiving groove 52 have the same orientation.
In the present embodiment, the housing 5 is integrally formed by aluminum with a high heat dissipation effect, and may be processed by a hot-melt forming technique or a milling machine forming technique.
The annular magnetic core 1 wound with the primary winding 2 and the secondary winding is disposed in the first accommodation groove 51, and the connection plate 211 of the pin 21 is exposed out of the first accommodation groove 51. The annular magnetic core 1 wound with the primary winding 2 and the secondary winding is configured in the first accommodating groove 51 by adopting a vacuum encapsulation technology, an OT terminal of the secondary winding is led out during vacuum encapsulation, the first accommodating groove 51 is filled with the potting adhesive, and the connecting plates 211 of the twelve pins 21 are exposed out of the potting adhesive after the vacuum encapsulation, so that subsequent connection can be realized.
The three resonant inductors 4 are respectively disposed in the three second receiving grooves 52, and are configured by using a vacuum encapsulation technique. The potting adhesive fills the three second receiving grooves 52, and similarly, in the process of realizing vacuum potting, the OT terminal is led out of the second receiving grooves 52 so as to realize subsequent connection.
Referring to fig. 1, 2 and 6, the magnetic integrated structure further includes a circuit board 6, and the circuit board 6 has a connection terminal 62 and a transition shunt for connecting the lead 21 and the connection terminal 62.
In the present embodiment, the circuit board 6 is specifically selected as a PCB board, and the overall shape of the circuit board 6 is a circumscribed rectangle of the open shape of the housing 5, so that the circuit board 6 can cover the housing 5. The switching shunt is etched on the front surface of the circuit board 6, and twelve abdicating grooves 61 penetrating through the front surface and the back surface are arranged on the circuit board 6 opposite to the connecting plates 211 of the twelve pins 21, so that the connecting plates 211 of the twelve pins 21 can penetrate to the front surface of the circuit board 6 from the back surface of the circuit board 6, and are connected to the circuit board 6 in a welding manner, and meanwhile, the connection with the switching shunt is realized. There are two sets of connection terminals 62, each set of connection terminals 62 includes three pairs, i.e., there are six pairs of connection terminals 62, and each pair of two connection terminals 62 are disposed close to each other, and the six pairs of connection terminals 62 are disposed at the edge of the circuit board 6 so as to be connected to an external circuit.
The switching branch is used for realizing the connection between the connection board 211 of the two groups of pins 21 and the two groups of connection terminals 62, specifically, in each group of pins 21, the four pins 21 connected to the same-name end of the primary winding 2 are respectively connected to one of the three pairs of connection terminals 62, and the four pins 21 connected to the different-name end of the primary winding 2 are respectively connected to the other of the three pairs of connection terminals 62, so that the two groups of six pairs of pins 21 and the two groups of six pairs of connection terminals 62 can be correspondingly connected, the two groups of connection terminals 62 can synchronously control the two groups of primary windings 2, and the synchronous control of the two groups of ten primary windings 2 can be equivalently realized.
Referring to fig. 6 and 7, in practical application, the magnetic integrated structure may be driven by a driving circuit, the driving circuit includes two sets of H-bridge switching circuits, the two sets of H-bridge switching circuits are connected in series to the power supply, each set of H-bridge switching circuit includes three H-bridge switching circuits connected in parallel, and the two sets of six H-bridge switching circuits can realize control of two sets of six pairs of connection terminals 62. Each group of H-bridge switching circuits is used to control one group of connection terminals 62, so that the two groups of H-bridge switching circuits can synchronously control the access potentials of the two groups of connection terminals 62.
In the figure, the shaded portions represent magnetic cores, and N1-N10 represent ten primary windings 2, wherein N1-N5 represent a first group of primary windings 2, and N6-N10 represent a second group of primary windings 2; NS1-NS3 represent three secondary windings, LS1-LS3 represent three resonant inductors 4; M11-M16 represent a first group of pins 21, M21-M26 represent a second group of primary windings 2, wherein M11, M13 and M15 represent synonym terminals of the first group of primary windings 2, M12, M14 and M16 represent homonym terminals of the first group of primary windings 2, M21, M23 and M25 represent synonym terminals of the second group of primary windings 2, and M22, M24 and M26 represent homonym terminals of the second group of primary windings 2; a11& B11-A13& B13 is a first set of three pairs of connecting terminals 62, A21& B21-A23& B23 is a second set of three pairs of connecting terminals 62; MS1 and MS2 represent two OT terminals; q111& Q112& Q113& Q114-Q131& Q132& Q133& Q134 is a first set of three H-bridge switching circuits, Q211& Q212& Q213& Q214-Q231& Q232& Q233& Q234 is a second set of three H-bridge switching circuits, where Q111 is connected to the positive pole of the dc power supply.
In a half control period, Q111& Q114-Q131& Q134 and Q211& Q214-Q231& Q234 are turned off, Q112& Q113-Q132& Q133 and Q212& Q213-Q232& Q233 are turned on, so that in two sets of six pairs of connecting terminals 62, the connecting terminal 62 connected to the same-name common terminal, i.e., a11-a13 and a21-a23, are connected to the positive pole of the dc power supply, the connecting terminal 62 connected to the different-name common terminal, i.e., B11-B13 and B21-B23, are connected to the negative pole of the dc power supply, i.e., the same-name terminal and the different-name terminal of each primary winding 2 are connected to the positive pole and the different-name terminal of the dc power supply, and the excitation voltages of the twelve primary windings 2 are both connected to the dc power supply, so that excitation currents with the same magnitude and direction are generated in the primary windings 2, and uniform magnetic fluxes in the first direction are generated in the ring-shaped magnetic core 1.
Induced currents with the same magnitude are generated in the three secondary windings, and the induced currents drive the resonant inductor 4 connected with the three secondary windings in series to work.
In the other half of the control period, Q111& Q114-Q131& Q134 and Q211& Q214-Q231& Q234 are turned on, Q112& Q113-Q132& Q133 and Q212& Q213-Q232& Q233 are turned off, so that the connecting terminals 62 connected with the same-name public terminals, namely A11-A13 and A21-A23, in the two groups of six pairs of connecting terminals 62 are connected with the negative pole of the direct current power supply, the connecting terminals 62 connected with the different-name public terminals, namely B11-B13 and B21-B23, are connected with the positive pole of the direct current power supply, namely, the homonymous terminal of each primary winding 2 is connected to the negative pole of the direct current power supply, the synonym terminal is connected to the positive pole of the direct current power supply, the excitation voltages of the twelve primary windings 2 are all inverse direct current power supplies, so that an opposite-phase excitation current with the same magnitude and direction is generated in the primary winding 2, and then a uniform magnetic flux in a second direction opposite to the first direction is generated in the annular magnetic core 1.
The three secondary windings generate opposite-phase induced currents with the same magnitude, and the resonant inductor 4 connected with the three secondary windings in series is driven to work by the opposite-phase induced currents.
In the above process, because two sets of six H-bridge switch circuits, two sets of six pairs of connection terminals 62, and two sets of ten primary windings 2 are all connected in parallel to the dc power supply, the dc power supply can be uniformly loaded, and the dc power supply has better balance, the voltage generated by the dc power supply can be uniformly distributed to the two sets of primary windings 2, the two sets of connection terminals 62, and the two sets of H-bridge switch circuits, and the generated current can be uniformly distributed to the three primary windings 2 of each set, the three pairs of connection terminals 62 of each set, and the three H-bridge switch circuits of each set, so that the magnetic integrated structure can withstand higher voltage and current. In a similar way, the secondary winding is uniformly distributed and wound on the annular magnetic core 1, the number of turns of the coil of the resonant inductor 4 is the same, so that the secondary winding and the resonant inductor 4 have better balance, and the secondary winding and the resonant inductor 4 can also bear higher voltage and current. In a word, the magnetic integrated structure has high balance, can bear higher voltage and current, and is favorable for prolonging the service life of the power module and improving the voltage resistance and current resistance of the power module when being applied to the power module.
Example two:
the present embodiment is different from the first embodiment in that the annular magnetic core 1 has three distributed air gaps 11 distributed circularly and symmetrically.
Example three:
the difference between this embodiment and the first embodiment is that the annular magnetic core 1 is a rectangular ring, and the annular magnetic core 1 is a UU type. Two pairs of distributed air gaps 11 are arranged on the rectangular annular magnetic core 1, and the two distributed air gaps 11 of each pair are centrosymmetric.
Example four:
the present embodiment is different from the first embodiment in that there are three sets of the primary winding 2, three sets of the pins 21, four sets of the pins, and seven pairs of the connection terminals 62. The number of the secondary windings and the number of the resonant inductors 4 are four, the four secondary windings are uniformly distributed and wound on the annular magnetic core 1, and the winding directions of the adjacent secondary windings are opposite.
Example five:
the difference between the present embodiment and the first embodiment is that the number of the secondary windings and the number of the resonant inductors 4 are two, the two secondary windings are uniformly wound on the quarter-ring magnetic core 1, and the two quarter-ring magnetic cores 1 where the two secondary windings are located are the same part or any two different parts.
In a second aspect, the embodiment of the application discloses a magnetic integration method of a voltage-spreading toroidal transformer and a resonant converter. The magnetic integration method comprises the following steps:
at least two groups of pins 21 are uniformly arranged on the annular magnetic core 1, the number of the pins 21 of each group of pins 21 is equal, and at least two pins 21 are arranged in each group;
relative to each group of pins 21, uniformly winding a primary winding 2 with the same coil turn number between every two adjacent pins 21, and when one group of primary windings 2 comprises more than one primary winding 2, cascading the primary windings 2 in the group of primary windings 2 end to end;
winding at least one secondary winding on the annular magnetic core 1;
the method comprises the following steps of (1) vacuum encapsulating an annular magnetic core 1 wound with a primary winding 2 and a secondary winding in a shell 5, and leading out one end of a pin 21 and two ends of the secondary winding;
aiming at each secondary winding, a leading-out end is connected with a resonant inductor 4;
welding and connecting one end of the pin 21, which is led out, by adopting a circuit board 6 which is pre-configured with a connecting terminal 62 and a switching shunt so as to enable the connecting terminal 62 to be connected with the pin 21; at least one pair of the connection terminals 62 is provided in each group, one of the pair of connection terminals 62 in each group of connection terminals 62 is connected to the homonymous terminals of all the primary windings 2 in the corresponding group through the transfer branch and the pin 21, and the other is connected to the synonym terminals of all the primary windings 2 in the group through the transfer branch and the pin 21.
Furthermore, the primary winding 2, the secondary winding and the resonant inductor 4 are wound by multiple strands.
Further, the resonant inductor 4 connected with the secondary winding is formed by winding a leading-out end of the secondary winding without breaking wires.
It should be understood that, on the basis of the realization of the magnetic integrated structure in the first aspect, a person skilled in the art can realize a corresponding magnetic integration method, and when the specific implementation mode of the magnetic integrated structure is different, the specific implementation mode of the magnetic integration method is changed correspondingly, but the person skilled in the art can realize the method according to the description of the present application, so that the magnetic integration method is not repeatedly disclosed.
In a third aspect, the embodiment of the application discloses a voltage-spreading toroidal transformer. This spread voltage toroidal transformer includes: a ring-shaped magnetic core 1, at least two groups of primary windings 2, at least one secondary winding and at least one group of connecting terminals 62;
the number of turns of the primary winding 2 is the same; each group of primary windings 2 comprises at least one primary winding 2, and the number of the primary windings 2 in different groups of primary windings 2 is the same; all the primary windings 2 are uniformly distributed and wound on the annular magnetic core 1, and when one group of primary windings 2 comprises more than one primary winding 2, the primary windings 2 of the same group are cascaded end to end in series;
one group of the connection terminals 62 corresponds to one group of the primary windings 2, the group of the connection terminals 62 comprises at least one pair of the connection terminals 62, one of the pair of the connection terminals 62 is connected with all the homonymous terminals of the corresponding group of the primary windings 2, and the other connection terminal is connected with all the synonym terminals of the corresponding group of the primary windings 2;
all the secondary windings are wound on the annular magnetic core 1.
Further, the annular magnetic core 1 is integrally formed or spliced into a circular or rectangular ring.
Further, distributed air gaps 11 are symmetrically arranged on the annular magnetic core 1.
Further, the primary winding 2 and the secondary winding are formed by winding multiple strands.
Further, the primary winding 2 and the secondary winding are formed by winding multiple strands.
Further, the ring transformer further comprises a shell 5, wherein the shell 5 is provided with a first accommodating groove 51, and the ring-shaped magnetic core 1 wound with the primary winding 2 and the secondary winding is arranged in the first accommodating groove 51 by adopting a vacuum encapsulation process.
Further, the ring transformer further comprises a circuit board 6, wherein a switching branch is configured on the circuit board 6, and the primary winding 2 and the connection terminal 62 are connected through the switching branch.
It should be understood that, on the basis of the realization of the magnetic integrated structure in the first aspect, a person skilled in the art can realize the toroidal transformer as a part of the magnetic integrated structure, and when the specific implementation of the magnetic integrated structure is different, the specific implementation of the toroidal transformer is changed accordingly, but the person skilled in the art can realize the toroidal transformer according to the description of the present application, so that the disclosure of the toroidal transformer is not repeated.
The above description is only a preferred embodiment of the application and is illustrative of the principles of the technology employed. It will be appreciated by those skilled in the art that the scope of the disclosure herein is not limited to the particular combination of features described above, but also encompasses other arrangements formed by any combination of the above features or their equivalents without departing from the spirit of the disclosure. For example, the above features may be replaced with (but not limited to) features having similar functions disclosed in the present application.

Claims (12)

1. A step-up toroidal transformer, comprising: the transformer comprises a ring-shaped magnetic core (1), at least two groups of primary windings (2), at least one secondary winding and at least two groups of connecting terminals (62);
the number of turns of the primary winding (2) is the same; each group of primary windings (2) comprises at least one primary winding (2), and the number of the primary windings (2) in different groups of primary windings (2) is the same; all the primary windings (2) are uniformly distributed and wound on the annular magnetic core (1), and when one group of primary windings (2) comprises more than one primary winding (2), the same group of primary windings (2) are cascaded end to end in series;
one group of connecting terminals (62) corresponds to one group of primary windings (2), the group of connecting terminals (62) comprises at least one pair of connecting terminals (62), one of the pair of connecting terminals (62) is connected with all homonymous terminals of the corresponding group of primary windings (2), and the other connecting terminal is connected with all synonym terminals of the corresponding group of primary windings (2);
all the secondary windings are wound on the annular magnetic core (1).
2. A voltage-spreading toroidal transformer according to claim 1, wherein said toroidal core (1) is integrally formed or spliced into a circular or rectangular ring.
3. A voltage-spreading toroidal transformer according to claim 1 or 2, wherein said toroidal core (1) is symmetrically provided with distributed air gaps (11).
4. A voltage-spreading toroidal transformer as claimed in claim 3, wherein said primary winding (2) and said secondary winding are formed by multi-strand winding.
5. A spread spectrum ring transformer as claimed in claim 1, further comprising a housing (5), said housing (5) having a first receiving slot (51), said annular magnetic core (1) wound with said primary winding (2) and secondary winding being disposed in said first receiving slot (51) using a vacuum potting process.
6. A spread spectrum ring transformer according to claim 1, further comprising a circuit board (6), wherein a switching shunt is disposed on said circuit board (6), and said primary winding (2) and said connection terminal (62) are connected via said switching shunt.
7. A magnetically integrated structure of a voltage-spreading toroidal transformer and a resonant converter, comprising a toroidal transformer as claimed in any one of claims 1 to 6, further comprising: resonance inductors (4) corresponding to the secondary windings of the toroidal transformer one by one;
one end of the resonance inductor (4) is connected with one end of the corresponding resonance inductor (4).
8. A magnetic integration structure of a voltage-spreading toroidal transformer and a resonant converter according to claim 7, wherein said resonant inductor (4) is formed by non-continuous winding of one end of the corresponding secondary winding.
9. A magnetic integration structure of a voltage-spreading toroidal transformer and a resonant converter as claimed in claim 7 or 8, wherein the housing (5) of the toroidal transformer further has a second receiving slot (52), and the resonant inductor (4) is disposed in the second receiving slot (52) by vacuum potting.
10. A magnetic integration method of a voltage-spreading toroidal transformer and a resonant converter is characterized by comprising the following steps:
at least two groups of pins (21) are uniformly arranged on the annular magnetic core (1), the number of the pins (21) of each group of pins (21) is equal, and at least two pins (21) are arranged in each group;
relative to each group of pins (21), primary windings (2) with the same number of turns of coils are uniformly wound between every two adjacent pins (21), and when one group of primary windings (2) comprises more than one primary winding (2), the primary windings (2) in one group of primary windings (2) are cascaded end to end;
winding at least one secondary winding on the annular magnetic core (1);
the method comprises the following steps that an annular magnetic core (1) wound with a primary winding (2) and a secondary winding is encapsulated in a shell (5) in a vacuum mode, and one end of a pin (21) and two ends of the secondary winding are led out;
aiming at each secondary winding, a leading-out end is connected with a resonant inductor (4);
welding and connecting one end of the pin (21) led out by adopting a circuit board (6) pre-configured with a connecting terminal (62) and a switching shunt so as to connect the connecting terminal (62) with the pin (21); at least one pair of the connecting terminals (62) in each group is provided, one of the pair of connecting terminals (62) in each group is connected with the homonymous terminals of all the primary windings (2) in the corresponding group through the switching shunt and the pin (21), and the other connecting terminal is connected with the synonym terminals of all the primary windings (2) in the group through the switching shunt and the pin (21).
11. The method of claim 10, wherein the primary winding (2), the secondary winding and the resonant inductor (4) are wound with multiple strands.
12. The method of claim 11, wherein the resonant inductor (4) connected to the secondary winding is formed by non-continuous winding of a terminal of the secondary winding.
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