CN114244073B - Voltage-expanding ring transformer and magnetic integration structure and method of voltage-expanding ring transformer and resonant converter - Google Patents
Voltage-expanding ring transformer and magnetic integration structure and method of voltage-expanding ring transformer and resonant converter Download PDFInfo
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- CN114244073B CN114244073B CN202111557109.1A CN202111557109A CN114244073B CN 114244073 B CN114244073 B CN 114244073B CN 202111557109 A CN202111557109 A CN 202111557109A CN 114244073 B CN114244073 B CN 114244073B
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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
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- 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
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- 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
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- 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
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- 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
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- 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
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- 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
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- 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
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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
- 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
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- 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 ring transformer, a magnetic integration structure and a method of the voltage-expanding ring 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 number of turns of coils, at least one secondary winding and at least two groups of connecting terminals; all primary windings in a group of primary windings are cascaded end to end, and all primary windings are uniformly wound on the annular magnetic core; each group of connection terminals is provided with at least one pair, one of the connection terminals of each pair is connected with all the homonymous ends of a corresponding group of primary windings, the other connection terminal is connected with all the heteronymous ends of the group of primary windings, and the secondary windings are wound on the annular magnetic core. The toroidal transformer is capable of expanding a voltage. 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 expanding voltage.
Description
Technical Field
The application relates to the technical field of magnetic integration, in particular to a voltage-expanding ring transformer and a magnetic integration structure and method of the voltage-expanding ring transformer and a resonant converter.
Background
The magnetic integration technology winds two or more discrete devices in the converter, such as an inductor, a transformer and the like, on a pair of magnetic cores, and is structurally concentrated together so as to reduce the volume and the weight of the magnetic devices in the power module, reduce current ripple and magnetic loss, improve the dynamic performance of the power module and have important significance for improving the performance and the power density of the power module.
With the increase of the power demand of the power supply module, the power supply module is required to have stronger voltage resistance, and higher requirements are also put on the voltage resistance of the magnetic integration technology.
Disclosure of Invention
The application provides a voltage-expanding ring transformer, a magnetic integration structure and a method of the voltage-expanding ring transformer and a resonant converter, and the voltage-expanding ring transformer is applied to a power module and can improve the voltage-resistant performance of the power module.
In a first aspect, the present application provides a step-up toroidal transformer. The structure comprises: the device 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 coils 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-tail cascade manner;
the group of connecting terminals correspond to the group of primary windings, the group of connecting terminals comprises at least one pair of connecting terminals, one of the 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;
all the secondary windings are wound on the annular magnetic core.
Through adopting above-mentioned technical scheme, when using, can adopt the H bridge switch circuit of multiunit series connection to connect many pairs of connecting terminals respectively, can realize the control to the direction of exciting current in the primary winding through H bridge switch circuit, the magnetic flux is annular in the guarantee annular magnetic core, the result of use is equivalent to all primary windings in series connection under a drive voltage, drive voltage can evenly apportion to at most H bridge switch circuit, many pairs of connecting terminal and many pairs of exciting coil, under the condition that the withstand voltage performance of every H bridge switch circuit, connecting terminal and primary coil equals, this annular transformer possesses can withstand higher voltage, possess more excellent withstand voltage performance promptly.
Further, the annular magnetic core is integrally formed or spliced to form a circular or rectangular ring.
Further, distributed air gaps are symmetrically arranged on the annular magnetic core.
Further, the primary winding and the secondary winding are formed by winding a plurality of strands of wires.
Further, the secondary winding and the corresponding resonant inductor are formed by winding a plurality of wires.
Further, the transformer further comprises a shell, wherein 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.
Further, the transformer further comprises a circuit board, wherein a transfer shunt is configured on the circuit board, and the primary winding and the connecting terminal are connected through the transfer shunt.
In a second aspect, the present application provides a magnetically integrated structure of a step-up toroidal transformer and a resonant converter, the structure comprising: the toroidal transformer of any one of the first aspects above, further comprising: resonant inductors corresponding to secondary windings of the ring transformer one by one;
one end of the resonant inductor is connected with one end of the corresponding resonant inductor.
Further, the resonant inductor is formed by winding one end of the corresponding secondary winding continuously.
Further, the shell of the annular transformer is also provided with a second accommodating groove, and the resonant inductor is arranged in the second accommodating groove by adopting a vacuum filling and sealing process.
In a third aspect, the present application provides a method of magnetically integrating a step-up toroidal transformer with a resonant converter. The method comprises the following steps:
uniformly configuring at least two groups of pins on the annular magnetic core, wherein the number of pins of each group of pins is equal, and each group of pins has at least two pins;
the method comprises the steps that (1) corresponding to each group of pins, primary windings with the same number of turns of coil are uniformly wound between every two adjacent pins, and when one group of primary windings comprises more than one primary winding, the primary windings in one group of primary windings are cascaded 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;
for each secondary winding, a leading-out end is adopted to be connected with a resonant inductor;
a circuit board with a pre-configured connecting terminal and a switching shunt is adopted to be welded and connected with one end of the pin leading out, so that the connecting terminal is connected with the pin; and one of the pair of connecting terminals in each group of connecting terminals is connected with the homonymous ends of the corresponding group of all primary windings through a switching shunt and a pin, and the other is connected with the heteronymous ends of the group of all primary windings through the switching shunt and the pin.
Further, the primary winding, the secondary winding and the resonant inductor are all wound by multiple strands of wires.
Further, the resonant inductor connected with the secondary winding is formed by winding a leading-out end of the secondary winding continuously.
In summary, the present application at least comprises one of the following beneficial effects:
1. provided are a toroidal transformer capable of improving withstand voltage performance of a power module and a magnetic integration structure and method thereof with a resonant converter;
2. the primary winding, the secondary winding and the resonant inductor are wound by multiple strands of wires, so that the uniformity of exciting current is improved, and the loss of the proximity effect and the eddy current loss are reduced;
3. the secondary winding and the resonance inductor are wound continuously by adopting the secondary winding, so that welding spots with larger sectional areas do not exist between the secondary winding and the resonance inductor, the loss of proximity effect caused by the welding spots can be avoided, a series of problems such as heating and fusing of the welding spots possibly caused can be avoided, the performance of the power module is further improved, and the service life of the power module is prolonged.
It should be understood that the description in this summary is not intended to limit key or critical features of embodiments of the present application, nor is it intended to be used to limit the scope of the present application. Other features of the present application will become apparent from the description that follows.
Drawings
The above and other features, advantages and aspects of embodiments of the present application will become more apparent by reference to the following detailed description when taken in conjunction with the accompanying drawings. In the drawings, wherein like or similar reference numerals denote like or similar elements, in which:
FIG. 1 is a schematic diagram showing the overall structure of a magnetic integration structure of a step-up toroidal transformer and a resonant converter in accordance with a first embodiment of the present application;
FIG. 2 shows an exploded schematic view of the magnetic integration of a step-up toroidal transformer and a resonant converter in accordance with the first embodiment of the present application;
FIG. 3 is a schematic view showing the structure of a toroidal core in the first embodiment of the present application;
FIG. 4 shows a partial enlarged view of portion A of FIG. 2;
fig. 5 is a schematic structural view showing a resonant inductor and a toroidal core wound with a primary winding and a secondary winding assembled to a housing according to a first embodiment of the present application;
FIG. 6 shows a schematic electrical structure of a magnetic integration structure of a step-up toroidal transformer and a resonant converter in a first embodiment of the present application;
fig. 7 shows an electrical schematic diagram of a control circuit corresponding to the magnetic integration structure of the step-up toroidal transformer and the resonant converter in the first embodiment of the present application.
Reference numerals illustrate: 1. a toroidal core; 11. distributing an air gap; 2. a primary winding; 21. pins; 211. a connecting plate; 212. a connecting groove; 22. a mounting plate; 4. a resonant inductance; 5. a housing; 51. a first accommodating groove; 52. a second accommodating groove; 6. a circuit board; 61. a relief groove; 62. and a connection terminal.
Detailed Description
For the purposes of making the objects, technical solutions and advantages of the embodiments of the present application more clear, the technical solutions of 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 apparent that the described embodiments are some embodiments of the present application, but not all embodiments. All other embodiments, which can be made by one of ordinary skill in the art based on the embodiments herein without making any inventive effort, are intended to be within the scope of the present application.
In addition, the term "and/or" herein is merely an association relationship describing an association object, and means that three relationships may exist, for example, a and/or B may mean: a exists alone, A and B exist together, and B exists alone. In addition, the character "/" herein generally indicates that the front and rear associated objects are an "or" relationship.
The application provides a magnetic integration structure and a method of a voltage-expanding ring transformer and a resonant converter, and the technologies are applied to a power module and can improve the voltage-withstanding performance of the power module.
In a first aspect, embodiments of the present application disclose a magnetic integration structure of a step-up toroidal transformer and a resonant converter.
Embodiment one:
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 an annular magnetic core, which is formed by splicing two half annular magnetic cores, and an epoxy plate is disposed at the splicing position of the two half annular magnetic cores, so that two symmetrical distributed air gaps 11 are formed on the annular magnetic core 1. The presence of the distributed air gap 11 facilitates the magnetic flux balancing of the subsequently wound primary winding 2.
In this embodiment, the material of the toroidal core 1 may be specifically manganese-zinc power ferrite, and the thickness of the epoxy board may be specifically 0.6mm.
The two groups of round-edge rents are uniformly distributed and wound on the annular magnetic core 1, a group of pins 21 are arranged opposite to each group of primary-edge windings 2, each primary-edge winding 2 is positioned between two pins 21, and the groups of primary-edge windings 2 are cascaded end to end through the pins 21. In this embodiment, there are five primary windings 2 in each group, six pins 21 in each group, twelve pins 21 in total are circularly and symmetrically distributed in the annular magnetic core 1, one group of six pins 21 is close to each other, the other group of six pins 21 is close to each other, and five intervals between one group of six pins 21 are respectively provided with one group of five primary windings 2.
Referring to fig. 2 and 4, in order to facilitate the installation and fixation of twelve pins 21, a circular mounting plate 22 adapted to the overall shape of the toroidal core 1 is pre-configured, 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 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 formed by an L-shaped plate and the plate surface of the connecting plate 211. When the pins 21 are fixedly arranged on the mounting plate 22, the connecting plate 211 is erected on the plate surface of the mounting plate 22, and the notch of the connecting groove 212 is away from the plate surface of the mounting plate 22.
In actual installation, the mounting plate 22 is configured on one end face of the annular magnetic core 1, so that the pins 21 can be installed, twelve equivalent dividing grooves can be formed between the connecting plates 211 of the twelve pins 21, and the subsequent winding of the primary winding 2 and the secondary winding is facilitated.
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 a plurality of strands of wires. For a group of pins 21, each primary winding 2 is wound between two adjacent pins 21, and two ends of the primary winding 2 are respectively led into two connecting slots 212 opposite to the two adjacent pins 21, and are respectively welded with the connecting slots 212. The adjacent primary windings 2 are wound in opposite directions, so that the adjacent primary windings 2 are connected through two homonymous ends or through two heteronymous ends, i.e. a group of five primary windings 2 are cascaded end to end through a group of six pins 21. Of the twelve pins 21, pins 21 serving as connection of the homonymous terminal are spaced apart from pins 21 serving as connection of the heteronymous terminal. In this embodiment, the pins 21 are specifically copper and integrally formed.
Referring to fig. 1 and 2, three secondary windings are wound around a toroidal core 1 (not shown) respectively, and are uniformly distributed on the toroidal 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 play a role of division, twelve division grooves are formed in the toroidal core 1 by the connection plates 211 of the twelve pins 21, so that each of the three secondary windings is uniformly wound in four division grooves. Similarly, in order to increase the uniformity of the secondary winding, reduce the proximity effect, improve the coupling effect of the secondary winding and the primary winding 2, the secondary winding is wound by a plurality of strands of wires. In addition, for facilitating subsequent connection and configuration, both ends of each secondary winding are led out and a length of stranded wire is left at each end as needed.
The primary winding 2 and the secondary winding on the toroidal magnetic core 1 are wound, in this embodiment, the number of turns of the primary winding 2 is two, the number of turns of the secondary winding is twenty, and of course, the number of turns of the primary winding 2 and the secondary winding can be specifically determined according to the requirement of the transformation ratio and the specifications of the multiple-strand and toroidal 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. Likewise, to increase the uniformity of the resonant inductor 4 and reduce the proximity effect, the resonant inductor 4 is also wound with multiple strands of wires. In addition, since the resonant inductor 4 and the secondary winding are stranded wires, and the secondary winding needs to be connected with the resonant inductor 4, in order to eliminate the connection point between the secondary winding and the resonant inductor 4, the stronger proximity effect of the connection point with a larger cross section area is avoided, in this embodiment, the resonant inductor 4 is specifically wound by the stranded wires led out from the homonymous end of the secondary winding continuously, 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 and the resonant inductor 4 which are connected in series are respectively led out and respectively provided with an OT terminal.
The above realizes the magnetic integration of the resonant inductor 4 in the resonant converter with the primary winding 2 and the secondary winding in the toroidal transformer, and the other parts of the resonant converter are not described herein, since the present application does not relate to improvements of the other parts of the resonant converter.
Referring to fig. 2 and 5, the magnetic integrated structure further includes a housing 5, and after the winding work of the primary winding 2 and the secondary winding on the toroidal core 1 is completed, the toroidal core 1 wound with the primary winding 2 and the secondary winding may be disposed in the housing 5; after the winding work of the resonant inductor 4 is completed, the wound resonant inductor 4 may be disposed in the housing 5.
For realizing magnetic integration, the whole shell 5 is shaped like a combination of a cylindrical part and a cuboid part, and specifically, the heights of the cylindrical part and the cuboid part are equal, the diameter of the cylindrical part is equal to the length of the cuboid part, and the two ends of the cylindrical part are flush with the two ends of the cuboid part in the height direction. 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 the inside is partitioned by two partition portions to form three rectangular parallelepiped second accommodation grooves 52 arranged along the length of the rectangular parallelepiped portion. The first accommodation groove 51 and the second accommodation groove 52 face the same direction.
In this embodiment, the housing 5 is integrally formed of aluminum with a high heat dissipation effect, and may be specifically manufactured by a hot melt forming technique or a milling machine forming technique.
The toroidal core 1 wound with the primary winding 2 and the secondary winding is disposed in the first accommodating groove 51, and the connection plate 211 of the pin 21 is exposed out of the first accommodating groove 51. The annular magnetic core 1 wound with the primary winding 2 and the secondary winding adopts a vacuum filling and sealing technology to realize the configuration in the first accommodating groove 51, and the OT terminal of the secondary winding is led out during vacuum filling and sealing, so that the filling and sealing glue fills the first accommodating groove 51, and the connecting plates 211 of twelve pins 21 are exposed out of the filling and sealing glue after vacuum filling and sealing, so that the subsequent connection can be realized.
The three resonant inductors 4 are respectively arranged in the three second accommodating grooves 52, and the configuration is realized by adopting a vacuum encapsulation technology. The potting adhesive fills up the three second accommodating grooves 52, and similarly, in the process of implementing vacuum potting, the OT terminal is led out of the second accommodating grooves 52 so as to implement 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 connection terminals 62 thereon and a switching shunt for connecting the pins 21 and the connection terminals 62.
In this embodiment, the circuit board 6 is specifically selected to be 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, twelve relief grooves 61 penetrating through the front surface and the back surface are formed in the connecting plate 211 of the circuit board 6 corresponding to the twelve pins 21, so that the connecting plate 211 of the twelve pins 21 can penetrate through the front surface of the circuit board 6 from the back surface of the circuit board 6 and be welded and connected to the circuit board 6, and meanwhile connection with the switching shunt is achieved. The connection terminals 62 have two groups, each group of connection terminals 62 includes three pairs, i.e. six pairs of connection terminals 62, and each pair of two connection terminals 62 are disposed close to each other, so as to facilitate connection with an external circuit, and the six pairs of connection terminals 62 are disposed at the edge of the circuit board 6 in a distributed manner.
The switching shunt is used for realizing connection of the connection plates 211 of the two groups of pins 21 and the two groups of connection terminals 62, specifically, in each group of pins 21, four pins 21 connected with the same name end of the primary winding 2 are respectively connected with one of a group of three pairs of connection terminals 62, four pins 21 connected with the different name end of the primary winding 2 are respectively connected with the other one of the group of three pairs of connection terminals 62, so that corresponding connection of two groups of six pairs of pins 21 and two groups of six pairs of connection terminals 62 can be realized, synchronous control of the two groups of primary windings 2 by the two groups of connection terminals 62 can be realized, and 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 driving circuit may be used to drive the magnetic integrated structure to work, where the driving circuit includes two groups of H-bridge switch circuits, and the two groups of H-bridge switch circuits are connected in series to the power supply, and each group of H-bridge switch circuits includes three H-bridge switch circuits connected in parallel, and the two groups of six H-bridge switch circuits can implement control over the two groups of six pairs of connection terminals 62. Each group of H-bridge switch circuits is used for controlling one group of connection terminals 62, so that synchronous control of the two groups of H-bridge switch circuits on the access potentials of the two groups of connection terminals 62 can be realized.
In the figure, the shaded portion represents a magnetic core, N1-N10 represent ten primary windings 2, where N1-N5 are a first set of primary windings 2 and N6-N10 are a second set of primary windings 2; NS1-NS3 represent three secondary windings and LS1-LS3 represent three resonant inductors 4; M11-M16 represents a first group of pins 21, M21-M26 represents a second group of primary windings 2, wherein M11, M13 and M15 represent the synonym ends of the first group of primary windings 2, M12, M14 and M16 represent the synonym ends of the first group of primary windings 2, M21, M23 and M25 represent the synonym ends of the second group of primary windings 2, and M22, M24 and M26 represent the synonym ends of the second group of primary windings 2; a11& B11-A13& B13 are the first set of three pairs of connection terminals 62, and A21& B21-A23& B23 are the second set of three pairs of connection terminals 62; MS1 and MS2 represent two OT terminals; q111& Q112& Q113& Q114-Q131& Q132& Q133& Q134 are the first set of three H-bridge switching circuits, and Q211& Q212& Q213& Q214-Q231& Q232& Q233& Q234 are the second set of three H-bridge switching circuits, wherein 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 of the two groups of six pairs of connection terminals 62, connection terminals 62 connected with the common terminal of the same name, namely A11-A13 and A21-A23, are connected to the positive pole of the direct current power supply, connection terminals 62 connected with the common terminal of the different name, namely B11-B13 and B21-B23, are connected to the negative pole of the direct current power supply, namely the common terminal of each primary winding 2 is connected to the positive pole of the direct current power supply, the exciting voltages of the twelve primary windings 2 are all direct current power supplies, and therefore exciting currents with the same magnitude and direction are generated in the primary windings 2, and then uniform magnetic fluxes with the first direction are generated in the annular magnetic core 1.
The three secondary windings generate induced currents with the same size, and the resonant inductor 4 connected in series with the three secondary windings is driven to work by the induced currents.
In the other half 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 of the two six pairs of connection terminals 62, connection terminals 62 connected to the common terminal of the same name, namely a11-a13 and a21-a23, are all connected to the negative pole of the direct current power supply, connection terminals 62 connected to the common terminal of the different name, namely B11-B13 and B21-B23, are all connected to the positive pole of the direct current power supply, namely the common terminal of each primary winding 2 is all connected to the positive pole of the direct current power supply, and the exciting voltages of the twelve primary windings 2 are all inverted direct current power supplies, thereby generating inverted exciting currents of the same magnitude and direction in the primary windings 2, and then generating uniform magnetic fluxes of the second direction opposite to the first direction in the toroidal magnetic core 1.
The three secondary windings generate the same reverse induction current, and the resonant inductor 4 connected in series with the reverse induction current is driven to work by the reverse induction current.
In the above process, since the two sets of six H-bridge switching circuits, the two sets of six pairs of connection terminals 62 and the 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 has better balance, the voltage generated by the dc power supply can be evenly distributed to the two sets of primary windings 2, the two sets of connection terminals 62 and the two sets of H-bridge switching circuits, and the generated current can be evenly 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 switching circuits of each set, so that the magnetic integrated structure can withstand higher voltage and current. Similarly, the secondary winding is uniformly distributed and wound on the annular magnetic core 1, and 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 also have better balance, and the secondary winding and the resonant inductor 4 can also withstand higher voltage and current. In a word, the balance of the magnetic integrated structure is higher, and the magnetic integrated structure can withstand higher voltage and current, and is applied to the power module, so that the service life of the power module and the voltage resistance and the current resistance of the power module are improved.
Embodiment two:
the difference between this embodiment and the first embodiment is that the toroidal core 1 has three circularly symmetrically distributed air gaps 11.
Embodiment III:
the present embodiment differs from the first embodiment in that the toroidal core 1 is a rectangular ring, and the toroidal core 1 is of 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.
Embodiment four:
the difference between this embodiment and the first embodiment is that the primary winding 2 has three groups of three pins 21 and four groups of four pins, and the connection terminals 62 have seven pairs. Four secondary windings and four resonant inductors 4 are uniformly distributed and wound on the annular magnetic core 1, and the winding directions of the adjacent secondary windings are opposite.
Fifth embodiment:
the difference between the first embodiment and the second embodiment is that the number of secondary windings and the number of resonant inductors 4 are two, the two secondary windings are uniformly wound on the quarter-ring-shaped magnetic core 1, and the two quarter-ring-shaped magnetic cores 1 where the two secondary windings are located are the same part or any two different parts.
In a second aspect, embodiments of the present application disclose a method of magnetically integrating a step-up toroidal transformer with 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 pins 21 of each group of pins 21 is equal, and each group of pins 21 has at least two pins;
the primary winding 2 with the same number of turns of coil is uniformly wound between every two adjacent pins 21 relative to each group of 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;
vacuum encapsulating the annular magnetic core 1 wound with the primary winding 2 and the secondary winding in the shell 5, and leading out one end of the pin 21 and two ends of the secondary winding;
for each secondary winding, a leading-out end is adopted to be connected with a resonant inductor 4;
a circuit board 6 with a pre-configured connecting terminal 62 and a switching shunt is adopted to be welded and connected with one end of the pin 21 led out, so that the connecting terminal 62 is connected with the pin 21; at least one pair of connection terminals 62 is provided in each group, one connection terminal 62 in each group of connection terminals 62 is connected with the homonymous ends of the corresponding group of all primary windings 2 through a switching shunt and a pin 21, and the other connection terminal is connected with the heteronymous ends of the group of all primary windings 2 through a switching shunt and a pin 21.
Further, the primary winding 2, the secondary winding and the resonant inductor 4 are all wound by multiple strands of wires.
Further, the resonant inductor 4 connected with the secondary winding is formed by winding a leading-out end of the secondary winding continuously.
It should be understood that, on the basis that the magnetic integration structure of the first aspect can be implemented, those skilled in the art can implement a corresponding magnetic integration method, and when the specific embodiments of the magnetic integration structure are different, the specific embodiments of the magnetic integration method correspondingly vary, but those skilled in the art can implement the magnetic integration method according to the disclosure of the present application, so that the magnetic integration method is not repeatedly disclosed.
In a third aspect, embodiments of the present application disclose a step-up toroidal transformer. The step-up voltage ring transformer includes: a toroidal core 1, at least two sets of primary windings 2, at least one secondary winding and at least one set of connection terminals 62;
the number of turns of the coils of the primary winding 2 is the same; each set of primary windings 2 comprises at least one primary winding 2, the number of primary windings 2 in different sets of primary windings 2 being 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 connected in cascade end to end;
the group of connection terminals 62 corresponds to the group of primary windings 2, the group of connection terminals 62 comprises at least one pair of connection terminals 62, one of the pair of connection terminals 62 is connected with all homonymous ends of the corresponding group of primary windings 2, and the other is connected with all heteronymous ends of the corresponding group of primary windings 2;
all the secondary windings are wound around the toroidal core 1.
Further, the annular magnetic core 1 is integrally formed or spliced to form a circular or rectangular ring.
Further, the annular magnetic core 1 is symmetrically provided with a distributed air gap 11.
Further, the primary winding 2 and the secondary winding are formed by winding a plurality of strands of wires.
Further, the primary winding 2 and the secondary winding are formed by winding a plurality of strands of wires.
Further, the toroidal transformer further comprises a housing 5, the housing 5 is provided with a first accommodating groove 51, and the toroidal 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 toroidal transformer further comprises a circuit board 6, and the circuit board 6 is provided with a switching shunt, and the primary winding 2 and the connection terminal 62 are connected through the switching shunt.
It should be understood that, on the basis that the magnetic integrated structure of the first aspect can be implemented, those skilled in the art can implement the toroidal transformer as a part of the magnetic integrated structure, and when the specific embodiments of the magnetic integrated structure are different, the specific embodiments of the toroidal transformer correspondingly vary, but those skilled in the art can implement the toroidal transformer according to the description of the present application, so that repeated disclosure of the toroidal transformer is not made.
The foregoing description is only of the preferred embodiments of the present application and is presented as a description of the principles of the technology being utilized. It will be appreciated by persons skilled in the art that the scope of the disclosure referred to in this application is not limited to the specific combinations of features described above, but it is intended to cover other embodiments in which any combination of features described above or equivalents thereof is possible without departing from the spirit of the disclosure. Such as the above-described features and technical features having similar functions (but not limited to) disclosed in the present application are replaced with each other.
Claims (10)
1. A magnetically integrated structure of a step-up toroidal transformer and a resonant converter, the step-up toroidal transformer comprising: a toroidal core (1), at least two sets of primary windings (2), at least one secondary winding and at least two sets of connection terminals (62);
the number of turns of the coils 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 connected in series in a head-tail cascade manner;
the group of connecting terminals (62) corresponds to the group of primary windings (2), the group of connecting terminals (62) comprises at least one pair of connecting terminals (62), one of the connecting terminals (62) is connected with all homonymous ends of the corresponding group of primary windings (2), and the other connecting terminal is connected with all heteronymous ends of the corresponding group of primary windings (2);
all the secondary windings are wound on the annular magnetic core (1);
further comprises: resonant inductors (4) which are in one-to-one correspondence with secondary windings of the toroidal transformer;
one end of the resonant inductor (4) is connected with one end of the corresponding secondary winding;
the magnetic integration structure of the voltage expansion ring transformer and the resonant converter is used for magnetic integration according to the following method:
at least two groups of pins (21) are uniformly arranged on the annular magnetic core (1), the number of pins of each group of pins (21) is equal, and each group of pins (21) has at least two pins;
the method comprises the steps that (1) corresponding to each group of pins (21), primary windings (2) with the same number of coil turns 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 are cascaded end to end;
winding at least one secondary winding on the annular magnetic core (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;
for each secondary winding, a leading-out end is adopted to be connected with a resonant inductor (4);
a circuit board (6) which is preconfigured with a connecting terminal (62) and a switching shunt is adopted to be welded with one end led out of the pin (21), so that the connecting terminal (62) is connected with the pin (21); at least one pair of connecting terminals (62) is arranged in each group, one of the connecting terminals (62) in each group is connected with the homonymous ends of all the corresponding primary windings (2) in the group through a switching shunt and a pin (21), and the other connecting terminal is connected with the heteronymous ends of all the primary windings (2) in the group through the switching shunt and the pin (21).
2. A magnetic integration structure of a step-up toroidal transformer and a resonant converter according to claim 1, characterized in that the toroidal core (1) is integrally formed or spliced into a circular or rectangular ring.
3. A magnetically integrated structure of a step-up toroidal transformer and a resonant transformer according to claim 1 or 2, characterized in that the toroidal core (1) is symmetrically provided with a distributed air gap (11).
4. A magnetically integrated structure of a step-up toroidal transformer and a resonant converter according to claim 3, characterized in that the primary winding (2) and the secondary winding are formed by multi-strand wire winding.
5. The magnetic integration structure of the step-up toroidal transformer and the resonant converter according to claim 1, further comprising a housing (5), wherein the housing (5) has a first accommodating groove (51), and the toroidal core (1) wound with the primary winding (2) and the secondary winding is disposed in the first accommodating groove (51) by a vacuum encapsulation process.
6. The magnetic integration structure of a step-up toroidal transformer and a resonant converter according to claim 1, further comprising a circuit board (6), wherein a switching shunt is arranged on the circuit board (6), and wherein the primary winding (2) and the connection terminal (62) are connected through the switching shunt.
7. A magnetically integrated structure of a step-up toroidal transformer and a resonant converter according to claim 1, characterized in that said resonant inductor (4) is formed by continuous winding of one end of the corresponding secondary winding.
8. The magnetic integration structure of the voltage-expanding ring transformer and the resonant converter according to claim 1 or 7, wherein the shell (5) of the ring transformer is further provided with a second accommodating groove (52), and the resonant inductor (4) is arranged in the second accommodating groove (52) by adopting a vacuum filling and sealing process.
9. The magnetic integration structure of the voltage-expanding ring transformer and the resonant converter according to claim 1, wherein the primary winding (2), the secondary winding and the resonant inductor (4) are all wound by multi-strand wires.
10. The magnetic integration structure of the voltage-expanding ring transformer and the resonant converter according to claim 9, wherein the resonant inductor (4) connected with the secondary winding is formed by continuous winding of a leading-out end of the secondary winding.
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