CN114944760A - 具有承载次级侧整流器组件的pcb的功率转换器变压器模块 - Google Patents

具有承载次级侧整流器组件的pcb的功率转换器变压器模块 Download PDF

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CN114944760A
CN114944760A CN202210139014.6A CN202210139014A CN114944760A CN 114944760 A CN114944760 A CN 114944760A CN 202210139014 A CN202210139014 A CN 202210139014A CN 114944760 A CN114944760 A CN 114944760A
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power converter
power
pcb
transformer
coil
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俞杭冬
黄海
陆宏亮
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Bel Fuse Macao Commercial Offshore Ltd
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    • H02M3/00—Conversion of dc power input into dc power output
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    • H02M3/33576—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 several active switching elements having at least one active switching element at the secondary side of an isolation transformer
    • H02M3/33592—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 several active switching elements having at least one active switching element at the secondary side of an isolation transformer having a synchronous rectifier circuit or a synchronous freewheeling circuit at the secondary side of an isolation transformer
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Abstract

一种功率转换器包括：功率变压器，具有容纳两个次级绕组的主体，该主体具有相对且基本平行的第一平面和第二平面，次级绕组中的每一个具有相应的第一线圈和第二线圈，该第一线圈和第二线圈具有相应的端子。第一线圈的端子延伸穿过变压器主体的第一面，并且第二线圈的端子延伸穿过变压器主体的第二面。转换器还包括：两个印刷电路板(PCB)，每个印刷电路板(PCB)设置在变压器主体的对应面处，每个PCB承载与相应的次级绕组的线圈的端子连接的相应的整流器电路的开关和电容器，每个PCB包括用于并联连接整流器电路以形成功率转换器的输出的外部连接。

Description

具有承载次级侧整流器组件的PCB的功率转换器变压器模块
技术领域
本发明涉及功率转换器的领域，并且具体涉及诸如提供大功率和大电流输出的高压DC(HVDC)转换器之类的DC/DC隔离转换器的领域。
发明内容
公开了一种功率转换器，包括：功率变压器，具有容纳两个次级绕组的主体，该主体具有相对且基本平行的第一平面和第二平面，次级绕组中的每一个具有相应的第一线圈和第二线圈，该第一线圈和第二线圈具有相应的端子。第一线圈的端子延伸穿过变压器主体的第一面，并且第二线圈的端子延伸穿过变压器主体的第二面。转换器还包括：两个印刷电路板(PCB)，每个印刷电路板(PCB)设置在变压器主体的对应面处，每个PCB承载与相应的次级绕组的线圈的端子连接的相应的整流器电路的开关和电容器，每个PCB包括用于并联连接整流器电路以形成功率转换器的输出的外部连接。
附图说明
从如附图所示的以下本发明的具体实施例的描述中，以上内容以及其他目的、特征和优点将变得显而易见，附图中相似的附图标记在不同视图中指代相同的部件。
图1-图3是本领域已知的具有不同变压器布置的高压DC(HVDC)电源的示意图；
图4是根据本发明的实施例的功率变压器模块的透视图；
图5是根据本发明的另一实施例的功率变压器模块的透视图；
图6是根据本发明的另一实施例的包括母线和磁线圈的功率变压器模块的透视图；
图7是安装在可以是主板的印刷电路板上的功率变压器模块的透视图；
图8是根据本发明的实施例的可以使用功率变压器模块来实现的谐振HVDC转换器的示意图；
图9是图8的HVDC转换器使用二极管整流代替同步整流器的版本；
图10是图7的功率变压器模块的透视图，包括PCB2对次级绕组NS1、NS2进行的连接的示意表示；
图11是功率变压器模块的功率变压器内部的分解图；
图12是图11的功率变压器内的单个线圈组的分解图；
图13是制造功率变压器的方法和产生的内部结构的图；以及
图14是采用相移初级侧全桥的谐振HVDC转换器的示意图。
具体实施方式
概述
开关电源以其体积小、重量轻、效率高的优点而广受欢迎，HVDC隔离转换器广泛地用于诸如通信和设备控制之类的各种领域。HVDC转换器的一种用途是用在某些AC电源中，这些电源使用两级转换器作为最终的DC输出。第一级是将AC转换为HDVC源极的功率因数校正(PFC)，并且第二级是将高电压转换为低电压的HVDC转换器。当使用优化的控制策略时，这种布置具有良好的输出特性。
随着各种宽带半导体器件的逐渐普及，第一级PFC电路的尺寸显著减小，从而导致前端(第一级)功率输入滤波器体积的减小。为了获得相应的整体尺寸减小，也希望减小第二级HVDC的尺寸。第二级HVDC的小型化可能会受到诸如效率、热性能和总成本之类的因素的限制。具体地，为了实现转换器的小型化，一种有效的措施是提高转换器的操作频率。但是如果频率太高，效率可能会相应地降低。同时，随着转换器的尺寸减小，热性能下降，这对转换器的热设计提出了更高的要求，并且对转换器的器件布局的可用空间提出了很大的挑战。
基于设计要求，HVDC转换器中的初级侧和次级侧能量转换变压器结构可以通过以下一般方式来实现：
1.一个转换器使用单个变压器进行能量转换。
2.一个转换器使用串联和并联的多个变压器来转换能量。
3.两个或多个并联的转换器(输出连接在一起)通过复杂的控制进行交错操作。
图1示出了上述具有单个变压器T1a的单变压器布置(1)的示例。这里，优点在于，在低输出电压和大电流的应用条件下，电路结构简单可靠并且成本低。然而，在转换器的小型化设计中，随着转换器的开关频率增大，趋肤效应越来越明显，尤其是对于次级侧铜绕组。因此，内部铜的有效铜截面积在次级绕组中没有得到充分利用。同时，减小变压器的尺寸也会影响热性能，因此需要在尺寸和热性能之间找到很好的平衡。否则，需要可靠的热设计。另外，当转换器的输出是大电流应用时，大量的表面贴装(SMD)开关需要安装在次级侧上，并且平衡开关和变压器的布局布置可能是一项挑战。
图2示出了串联-并联布置(2)的示例，该布置采用了两个变压器T2a和T2b，其中，该两个变压器的初级绕组串联，并且次级绕组并联。一般而言，两个或多个初级侧绕组串联连接，而对应的次级侧绕组并联连接。这种方法有效地简化了变压器内的绕组的结构设计，增加了散热面积，并且对变压器的热性能具有积极的影响。由于具有若干并联的绕组，单个变压器电流降低到初始的1/n，并且损耗也大大降低，这可以提高效率。并且缺点在于，总体积大，受安全要求限制，因此不容易布局。
图3示出了交错布置(3)的示例，该布置在对应的模块中采用了并联的两个变压器T3a和T3b。这里，理想情况下，两个模块都输出总功率的一半。通常，两个模块以180度异相切换，因此可以大大减少输入侧和输出侧上的高频电流纹波。可以降低AC和DC两者的损耗，并且相应地提高效率和热性能。缺点在于，与单变压器布置(1)相比，功率器件数增加了一倍；材料和生产成本相对较高；转换器的整体尺寸相对较大；小型化困难；以及，由于两个模块之间需要电流共享，因此控制策略复杂，并且可靠性可能相对较低。
现有转换器设计的另一个已知方面是将次级侧整流器开关安装在主板上。由于主板上安装了大量的通孔(THT)组件，主板外形可能较大。此外，出于成本原因，这样的主板通常可以使用不超过4层的PCB，并且因此主板的电流承载量是有限的。另外，主板可能位于风扇气流相对较低的电源底部，这对次级侧整流器开关的散热产生不利影响，并且因此影响整个单元的性能。
针对上述HVDC转换器的技术问题，提出了一种新的模块化设计构思，以解决HVDC成本、转换效率、整体尺寸和整体热性能之间的冲突。该设计通过结构优化组合了单变压器的低成本优势和双变压器的高效率特征，同时提高了模块的散热能力，确保了产品性能，控制了成本并提高了整体性能。
如本文所公开的，解决上述需求和缺点的一般方法是将功率转换器配置为包括：功率变压器，具有容纳两个次级绕组的主体，该主体具有相对且基本平行的第一平面和第二平面，次级绕组中的每一个具有相应的第一线圈和第二线圈，该第一线圈和第二线圈具有相应的端子。第一线圈的端子延伸穿过变压器主体的第一面，并且第二线圈的端子延伸穿过变压器主体的第二面。转换器还包括：两个印刷电路板(PCB)，每个印刷电路板(PCB)设置在变压器主体的对应面处，每个PCB承载与相应的次级绕组的线圈的端子连接的相应的整流器电路的开关和电容器，每个PCB包括用于并联连接整流器电路以形成功率转换器的输出的外部连接。这种布置可以提供上述成本和效率优势，包括改进的散热。
实施例
图4示出了根据一个实施例的用于功率转换器的功率变压器模块。它包括功率变压器T1和两个印刷电路板PCB1、PCB2。还可以看到用于变压器T1的初级绕组的两个初级侧导体PRI。变压器T1的非导电外部被称为“主体”(未单独编号)。该主体容纳初级绕组和两个次级绕组，该初级绕组和两个次级绕组除了初级侧导体PRI和次级绕组的两组TERM1、TERM2之外不可见，TERM1和TERM2从变压器主体的平行面延伸，并与PCB1和PCB2的对应特征(例如，通孔)相配合。下面提供了变压器T1的配置的附加细节。
总体而言，在这种布置中，功率变压器T1具有其输出(次级)绕组的沿相反方向(在图4中大致为左和右)延伸的线圈，并且变压器与两个多层PCB(PCB1、PCB2)组合以形成夹层结构或类似I的结构。如图5的附加示例所示，PCB1和PCB2均优选地承载相应的次级侧整流器电路，该次级侧整流器电路包括多个开关Q1～Qn和多个滤波电容器C1～Cn。在一个实施例中，PCB1和PCB2是两侧PCB，并且器件Qx和Cx是表面贴装器件(SMD)。
在变压器T1的每一侧上的输出线/端子TERM1、TERM2构成电路的对称结构，为负责正负半周期操作的电功率传输的两个次级绕组提供外部连接(参见下面的电路示例和变压器细节)。在本文的示例中，每个PCB上的开关Qx并联连接以形成更大有效尺寸(～n倍于单个开关的尺寸)的单个开关(“Q”)，并且类似地，每个PCB上的电容器Cx并联连接以用作具有更大有效尺寸(～n倍于单个电容器的尺寸)的单个电容器(“C”)。PCB1、PCB2中的每一个承载连接以形成两个整流器电路的一部分，该部分将电流从T1的次级绕组经由单独的母线引导到功率转换器输出，如下文中所描述的。对于次级绕组中的每一个，这些连接包括：
1.次级绕组的一端的次级端子TERM连接到开关Q的一端；
2.开关Q的另一端连接到电容器C的一端；
3.电容器C的另一端连接到次级绕组的另一端的次级端子TERM。
因此，变压器T1、开关Q和滤波电容器C这三个组件形成了高频电流电路。由于转换器的开关周期存在正负半周期对称性，并且正负半周期绕组中的每一个负责一半的功率传输，因此在PCB的同一侧上还有包括开关和滤波电容器的多个高频电流电路，并且数量为偶数。
整体结构可以通过调整功率变压器T1的初级侧和次级侧的匝数比、次级侧整流器开关的耐受电压和开关数来适应广泛应用的不同的输出电压和不同的输出功率。
功率变压器T1的载流子、电源开关Q和滤波电容器C是多层PCB(PCB1、PCB2)，并且对称地分布在功率变压器T1的两侧。根据电源的损耗量，可以灵活调整PCB的层数和厚度—层数越多，PCB铜越厚，使得载流能力越大，并且导热性越强。这种导热性越过多层PCB并进入主板M1，通过主板M1大面积的铜，有助于模块散热。
图5和图7示出了PCB1和PCB2均具有与功率变压器T1的次级绕组的端子TERMx相配合的上部，以及承载了到单独的主板M1的外部连接并且具有设置在其上的开关Q和电容器C的下部或底部。在一个实施例中，PCB底部边缘处的外部连接包括导电的镀金手指(“金手指”)，其直接焊接到主板M1的对应特征(例如，通孔)。如前所述，这种配置可以大大增加与主板M1的热交换能力，同时也降低了PCB1、PCB2和主板M1之间的焊接阻抗，降低了DC损耗。
在所示的布置中，功率开关Q安装在直立的PCB(PCB1、PCB2)上，并且不同数量的开关管封装可以布置在该PCB的两侧，这提供了功率扩展的灵活性，并且与在主板M1的顶部和底部上具有开关Q的传统布置相比，可以大大改善开关Q的散热效率。功率开关可以安装在两个多层PCB的内侧和外侧，并且在多个开关的情况下，所有开关都可以靠近功率变压器T1的端子TERMx放置，并且高频滤波电容器也靠近功率开关Q。这种布置可以最小化高频电流电路，并且降低由高频电流引起的AC损耗。
图6示出了根据需要可以在变压器T1的一侧上将母线(Busbar)添加到PCB1和PCB2之间，该母线提供PCB1的整流器电路与PCB2的整流器电路的并联连接，并且具有与主板的对应特征相配合的一个或多个中间端子(P1、P2)。根据需要，可以将一个或多个磁环B1(环形线圈)放置在母线上(例如，在如图所示的端子P1、P2上)，这可以有效地减少功率模块的输出的电流纹波，并降低外围器件的电流纹波压力。母线还可以使用多个磁环或磁芯来形成完整的独立电感器，该电感器可以用于不同的电路拓扑。
具有双向输出结构的功率变压器T1和承载整流器电路和滤波电路的紧密布置的PCB(PCB1、PCB2)的布置可以适用于多种转换器电路，尤其适用于在转换器的次级侧没有滤波电感器的谐振转换器(所谓的LLC谐振转换器)。
图8示出了具有全波整流的隔离式LLC谐振转换器电路的示例。主电路包括隔离式主功率变压器T1、同步整流器Q1、同步整流器Q2和电容器Cout。功率变压器T1具有初级侧绕组Np、第一次级侧绕组Ns1和第二次级侧绕组Ns2。第一次级侧绕组Ns1的带点端子连接到Q1同步整流器的漏极，第一次级侧绕组Ns1的非带点端子连接到第二次级侧绕组Ns2的带点端子，并且还连接到电容器Cout的一端，并且电容器Cout的另一端连接到同步整流器Q1的源极和同步整流器Q2的源极。第二次级侧绕组Ns2的非带点端子连接到同步整流器Q2的漏极。
图9示出了在次级侧上采用二极管整流(D1、D2)而不是开关晶体管(例如，图8中的Q1、Q2)的备选方案。通常，本文公开的结构不限于全桥或半桥LLC。上述母线可以选择性地安装在LLC谐振转换器中以形成小电感器，该小电感器与LLC转换器的输出电容器组合，可以有效地减少输出电流的高频纹波电流。
图10是图7的功率变压器模块的另一描述，包括PCB2对次级绕组NS1、NS2(具体地，对NS1和NS2的终止于PCB2的线圈；参见下文中的细节)进行的连接的示意性表示。将理解，PCB1对NS1和NS2的终止于PCB1的线圈进行类似的连接。
图11是功率变压器T1的某些部分的分解图。该功率变压器T1的绝缘主体具有顶部和底部，并且其内部包括四(4)组次级侧线圈。
图12示出了4个线圈组中的每一个都包括四个线圈(COIL1–COIL4)，这些线圈由散布有诸如绝缘纸之类的绝缘层的扁平的弧形导电构件(例如，铜片)形成。在每个组中，四个线圈构成NS1和NS2两者的一部分，并且如下延伸到PCB1或PCB2：
COIL1：NS2、PCB2
COIL2：NS1、PCB2
COIL3：NS2、PCB1
COIL4：NS1、PCB1
图13示出了制造变压器T1的方法和其产生的内部结构，从左侧上方开始，并沿着箭头所示的路径进行。首先制造初级绕组层，然后在该绕组上放置一个线圈组。将该操作再重复3次，从而形成散布有初级侧绕组层的四个线圈组的堆栈。初级侧绕组的暴露端(最后步骤)形成初级侧导体PRI，如图4所示。
图14示出了具有零电压开关(ZVS)功能的相移全桥电路，该相移全桥电路也适用于HVDC应用。可以通过适当地改变上述母线的结构并将其与适当的磁芯或磁环B1组合来将该母线制成固定电感器，该固定电感器在该应用中可以用作全桥转换器的输出降压电感器。
虽然已经具体示出和描述了本发明的各种实施例，但是本领域技术人员将理解，在不脱离所附权利要求限定的本发明的范围的情况下，可以进行形式和细节上的多种改变。

Claims (15)

1.一种功率转换器，包括：
功率变压器，具有容纳两个次级绕组的主体，所述主体具有相对且基本平行的第一平面和第二平面，所述次级绕组中的每一个具有相应的第一线圈和第二线圈，所述第一线圈和第二线圈具有相应的端子，所述第一线圈的端子延伸穿过所述变压器主体的第一面，并且所述第二线圈的端子延伸穿过所述变压器主体的第二面；以及
两个印刷电路板PCB，每个印刷电路板PCB设置在所述变压器主体的对应面处，每个PCB承载与相应的次级绕组的线圈的端子连接的相应的整流器电路的开关和电容器，每个PCB包括用于并联连接所述整流器电路以形成所述功率转换器的输出的外部连接。
2.根据权利要求1所述的功率转换器，还包括：主板，在所述变压器主体的底部处，并在所述PCB之间延伸，并且其中，所述PCB的外部连接设置在所述PCB的底部边缘处，并与所述主板的对应特征相配合。
3.根据权利要求2所述的功率转换器，其中，所述PCB中的每一个具有底部和上部，所述上部与所述功率变压器的相应的次级绕组的端子相配合，所述底部承载所述外部连接，并具有设置在所述底部上的开关和电容器。
4.根据权利要求2所述的功率转换器，还包括：母线，在所述变压器主体的底部处，并在所述PCB之间延伸，所述母线提供所述整流器电路的并联连接，并具有与所述主板的对应特征相配合的一个或多个中间端子。
5.根据权利要求2所述的功率转换器，其中，所述PCB的外部连接由从相应的边缘向下延伸到所述主板的导电指形成。
6.根据权利要求1所述的功率转换器，其中，所述功率变压器还包括：初级绕组，具有从所述主体延伸到所述PCB中的一个PCB的初级导体。
7.根据权利要求6所述的功率转换器，其中，所述一个PCB还包括：初级侧电路的附加组件，连接在所述功率转换器的输入和所述初级导体之间。
8.根据权利要求1所述的功率转换器，其中，在所述PCB的每一个上，所述开关并联连接以用作更大尺寸的单个开关，并且所述电容器并联连接以用作更大尺寸的单个电容器。
9.根据权利要求1所述的功率转换器，还包括：母线，在所述变压器主体的底部处，并在所述PCB之间延伸，所述母线提供所述整流器电路的并联连接以形成所述功率转换器的输出。
10.根据权利要求9所述的功率转换器，还包括：一个或多个环形线圈，在所述母线上，以提供与所述电容器的电容组合的电感，以减少输出电流的高频纹波电流。
11.根据权利要求1所述的功率转换器，其中，所述次级绕组的线圈被布置为多组，每组包括：(1)第一次级绕组的第一线圈，终止于第一PCB处；(2)所述第一次级绕组的第二线圈，终止于第二PCB处；(3)第二次级绕组的第一线圈，终止于所述第一PCB处；以及(4)所述第二次级绕组的第二线圈，终止于所述第二PCB处。
12.根据权利要求11所述的功率转换器，其中，所述线圈形成为扁平的弧形导电构件，并且所述组散布在所述功率变压器的初级绕组的相应的线圈部分中。
13.根据权利要求1所述的功率转换器，其中，所述开关是功率晶体管。
14.根据权利要求13所述的功率转换器，其中，所述功率晶体管是场效应晶体管。
15.根据权利要求1所述的功率转换器，其中，所述开关是功率二极管。
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