CN116580938A - Transformer and design method thereof - Google Patents
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- H—ELECTRICITY
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- 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
- 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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Abstract
A transformer and a design method thereof are provided, and relate to the field of power supplies. A cross-sectional area of one of the at least one second core portions of the first core of the transformer is calculated from a magnetic density of the first core, wherein the magnetic density of the first core is determined from a heat dissipation parameter of the first core; the cross-sectional area of one of the at least one second core portion of the second magnetic core of the transformer is calculated from the magnetic density of the second magnetic core, wherein the magnetic density of the second magnetic core is determined from the heat dissipation parameters of the second magnetic core. The volume of the transformer can be reduced on the basis of meeting the performance of the transformer, and the requirement of thermal design is met.
Description
Technical Field
The invention relates to the field of power supplies, in particular to a transformer and a design method thereof.
Background
The isolated power supply converter can realize the functions of power conversion and isolation, and can be widely applied to various application occasions, such as new energy automobiles, and can be used for converting the energy of a high-voltage battery into the energy of a low-voltage battery or used for converting alternating current into direct current for charging the high-voltage battery.
Heat dissipation is an important consideration for isolating power converters, especially in high power isolating power converters, where thermal design is a major consideration. The transformer is a main heating source in the isolated power converter, so heat dissipation of the transformer is an important point of the isolated power converter.
In addition, the volume is also an important point in consideration of the isolated power converter, and in general, the transformer is the largest device in the isolated power converter, so how to reduce the volume of the transformer is another important point in the interest of the isolated power converter.
Therefore, how to design a transformer with small volume and good heat dissipation effect becomes the key point of the design of the isolated power supply converter.
Disclosure of Invention
The transformer aims at the problem that the prior transformer is large in size. The application proposes a transformer comprising: a first magnetic core including a first magnetic core portion and at least one second magnetic core portion disposed at an angle to the first magnetic core portion, wherein a cross-sectional area of one of the at least one second magnetic core portion of the first magnetic core is calculated from a magnetic density of the first magnetic core, the magnetic density of the first magnetic core is determined from a heat radiation parameter of the first magnetic core, wherein a primary winding or a secondary winding of a transformer is wound on the first magnetic core; the second magnetic core comprises a first magnetic core part and at least one second magnetic core part which is arranged at an angle with the first magnetic core part, the at least one second magnetic core part of the second magnetic core is respectively abutted with the at least one second magnetic core part of the first magnetic core, wherein the cross section area of one of the at least one second magnetic core parts of the second magnetic core is obtained according to the magnetic density calculation of the second magnetic core, the magnetic density of the second magnetic core is determined according to the heat dissipation parameter of the second magnetic core, and the second magnetic core is correspondingly wound with a secondary side winding or a primary side winding of a transformer.
Optionally, when the primary winding of the transformer is wound on the first magnetic core and the secondary winding of the transformer is wound on the second magnetic core, the formula is given byCalculating a cross-sectional area of one of the at least one second core portions of the first core, wherein Vp (t) is applied to the first coreVoltage of primary winding of transformer, np is number of turns of primary winding, bp is magnetic density of the first magnetic core, aep is cross-sectional area of one of the at least one second magnetic core portion of the first magnetic core; according to the formula->Calculating a cross-sectional area of one of the at least one second core portions of the second magnetic core, wherein Vs (t) is a voltage applied to a secondary winding of the transformer, ns is a number of secondary winding turns, bs is a magnetic density of the second magnetic core, and Aes is a cross-sectional area of one of the at least one second core portions of the second magnetic core.
Optionally, when the secondary winding of the transformer is wound on the first magnetic core and the primary winding of the transformer is wound on the second magnetic core, the formula is given byCalculating a cross-sectional area of one of the at least one second core portions of the second magnetic core, wherein Vp (t) is a voltage applied to a primary winding of the transformer, np is a number of primary winding turns, bp is a magnetic density of the second magnetic core, and Aep is a cross-sectional area of one of the at least one second core portions of the second magnetic core; according to the formula- >Calculating a cross-sectional area of one of the at least one second core portions of the first magnetic core, wherein Vs (t) is a voltage applied to a secondary winding of the transformer, ns is a number of secondary winding turns, bs is a magnetic density of the first magnetic core, and Aes is a cross-sectional area of one of the at least one second core portions of the first magnetic core.
Optionally, one of the first magnetic core and the second magnetic core has a magnetic density that is less than the magnetic density of the other.
Optionally, the transformer further includes an integrally formed magnetic sheet, and the integrally formed magnetic sheet is disposed between the primary winding and the secondary winding.
Optionally, at least one of the at least one second core part of the first magnetic core is provided with a notch, and the notch is used for filling heat-dissipating glue so that the heat-dissipating glue contacts with the primary winding or the secondary winding wound on the first magnetic core; and a notch is arranged on at least one of the at least one second magnetic core part of the second magnetic core, and the notch is used for filling heat-dissipating glue so as to enable the heat-dissipating glue to be in contact with the secondary winding or the primary winding wound on the second magnetic core.
Optionally, the first magnetic core at least comprises a first sub-magnetic core and a second sub-magnetic core, and a heat conducting material is arranged between the first sub-magnetic core and the second sub-magnetic core; the second magnetic core at least comprises a third sub-magnetic core and a fourth sub-magnetic core, and a heat conducting material is arranged between the third sub-magnetic core and the fourth sub-magnetic core.
Optionally, dispensing is performed between the second core portions of at least one group of the first magnetic cores and the second core portions of the second magnetic cores, which are in contact with each other, and dispensing is not performed between the second core portions of at least one group of the first magnetic cores and the second core portions of the second magnetic cores, which are in contact with each other.
Optionally, the transformer further comprises a heat dissipation shell, wherein the heat dissipation shell is covered around the transformer, and heat dissipation glue is filled in the heat dissipation shell.
The application also provides a design method of the transformer, which comprises the following steps: providing a primary winding magnetic core, which is used for winding a primary winding of a transformer and comprises a first magnetic core part and at least one second magnetic core part which is arranged at an angle with the first magnetic core part, determining a heat dissipation parameter of the primary winding magnetic core, determining the magnetic density of the primary winding magnetic core according to the heat dissipation parameter of the primary winding magnetic core, and calculating the cross-sectional area of one of the at least one second magnetic core part of the primary winding magnetic core according to the magnetic density of the primary winding magnetic core; the method comprises the steps of providing a secondary winding magnetic core for winding a secondary winding of a transformer, wherein the secondary winding magnetic core comprises a first magnetic core part and at least one second magnetic core part which is arranged at an angle with the first magnetic core part, the at least one second magnetic core part of the secondary winding magnetic core is respectively abutted with the at least one second magnetic core part of the primary winding magnetic core, determining the heat dissipation parameter of the secondary winding magnetic core, determining the magnetic density of the secondary winding magnetic core according to the heat dissipation parameter of the secondary winding magnetic core, and calculating the cross-sectional area of one of the at least one second magnetic core parts of the secondary winding magnetic core according to the magnetic density of the secondary winding magnetic core.
Alternatively, according to the formulaCalculating a cross-sectional area of one of the at least one second core portions of the primary winding core, wherein Vp (t) is a voltage applied to a primary winding wound on the primary winding core, np is a number of primary winding turns, bp is a magnetic density of the primary winding core, and Aep is a cross-sectional area of one of the at least one second core portions of the primary winding core; according to the formula->Calculating a cross-sectional area of one of the at least one second core portions of the secondary winding core, wherein Vs (t) is a voltage applied to a secondary winding wound around the secondary winding core, ns is a number of secondary winding turns, bs is a magnetic density of the secondary winding core, and Aes is a cross-sectional area of one of the at least one second core portions of the secondary winding core.
Optionally, the second core portion of the first magnetic core for calculating the cross-sectional area and the second core portion of the second magnetic core for calculating the cross-sectional area are abutted against each other.
Optionally, providing an integrally formed magnetic sheet disposed between the primary winding wound on one of the at least one second core portions on the primary winding core and the secondary winding wound on one of the at least one second core portions on the secondary winding core is further included.
Optionally, at least one of the at least one second core parts of the primary winding magnetic core is provided with a notch, and the notch is used for filling heat-dissipating glue so as to enable the heat-dissipating glue to be in contact with a primary winding wound on the primary winding magnetic core; and a notch is arranged on at least one of the at least one second magnetic core parts of the secondary winding magnetic core and is used for filling heat-dissipating glue so that the heat-dissipating glue is in contact with the secondary winding wound on the secondary winding magnetic core.
Optionally, the primary winding magnetic core at least comprises a first secondary primary winding magnetic core and a second secondary primary winding magnetic core, and a heat conducting material is arranged between the first secondary primary winding magnetic core and the second secondary primary winding magnetic core; the secondary winding magnetic core at least comprises a third secondary winding magnetic core and a fourth secondary winding magnetic core, and a heat conduction material is arranged between the third secondary winding magnetic core and the fourth secondary winding magnetic core.
Optionally, the method further comprises a dispensing process, wherein the dispensing process dispenses glue between the second magnetic core parts of at least one group of the primary winding magnetic cores and the second magnetic core parts of the secondary winding magnetic cores which are mutually abutted, and the dispensing process keeps no glue between the second magnetic core parts of at least one group of the first magnetic cores and the second magnetic core parts of the second magnetic cores which are mutually abutted.
The application can realize at least one of the following beneficial effects:
the cross-sectional areas of the first magnetic core and the second magnetic core of the transformer are designed separately, so that the utilization rate of the first magnetic core and the utilization rate of the second magnetic core are improved, and the volume optimization of the transformer is ensured on the premise of ensuring reasonable temperature rise of the transformer.
The foregoing has outlined rather broadly the features and technical advantages of the present application in order that the detailed description of the application that follows may be better understood. Additional features and advantages of the application will be described hereinafter which form the subject of the claims of the application. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures or processes for carrying out the same purposes of the present application. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the application as set forth in the appended claims.
Drawings
For a more complete understanding of the present application, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 shows a schematic diagram of a typical isolated DC/DC converter;
fig. 2 shows an equivalent circuit schematic of a transformer of the isolated DC/DC converter of fig. 1;
FIG. 3 shows a schematic diagram of a transformer according to an embodiment of the application;
FIG. 4 is a schematic diagram of a power conversion device according to an embodiment of the present application;
FIG. 5 shows a schematic diagram of a transformer according to another embodiment of the present application;
FIG. 6 shows a schematic diagram of a prior art power conversion device;
fig. 7 shows an exploded schematic view of the transformer of fig. 3;
FIG. 8 is a schematic diagram of a transformer used in the power conversion apparatus of FIG. 4 according to an embodiment of the present application;
fig. 9 shows a schematic diagram of a power conversion device according to another embodiment of the present application.
Symbol description: vp (t), the voltage applied to the primary winding of the transformer; np, number of primary winding turns; bp, magnetic density of the first magnetic core; aep, a cross-sectional area of one of the at least one second core portions of the first magnetic core; vs (t), the voltage applied to the secondary winding of the transformer; ns, secondary winding turns; bs, magnetic density of the second magnetic core; aes, a cross-sectional area of one of the at least one second core portions of the second magnetic core.
Corresponding numerals and symbols in the various drawings generally indicate corresponding parts unless otherwise indicated. The drawings are not necessarily to scale in order to clearly illustrate the relevant aspects of the various embodiments.
Detailed Description
The following description of the embodiments of the present application will be made more apparent and fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the application are shown. All other embodiments, which can be made by those skilled in the art based on the embodiments of the application without making any inventive effort, are intended to be within the scope of the application.
Referring to fig. 1, a schematic diagram of a typical isolated DC/DC converter includes a primary switch unit 110, a transformer 130 and a secondary switch unit 120, wherein the primary switch unit 110 and the secondary switch unit 120 each include at least one switch tube, the transformer 130 includes a primary winding r1 and a secondary winding r2, two ends of the primary winding r1 are respectively connected to two ends of the primary switch unit 110, and two ends of the secondary winding r2 are respectively connected to two ends of the secondary switch unit 120.
Referring to fig. 2, as shown in fig. 2, vp (t) is a primary winding voltage applied to the primary winding r1, vs (t) is a secondary winding voltage Vs (t) applied to the secondary winding r2, lkp is an equivalent primary leakage inductance, lks is an equivalent secondary leakage inductance, lm is an excitation inductance,
The primary switching unit 110 is used to convert the first voltage V1 into a primary winding voltage Vp (t) applied to the primary winding r1 or to convert the primary winding voltage Vp (t) applied to the primary winding r1 into the first voltage V1. The secondary switching unit 120 converts the secondary winding voltage Vs (t) applied to the secondary winding r2 into the second voltage V2, or converts the second voltage V2 into the secondary winding voltage Vs (t) applied to the secondary winding r 2. The transformer 130 is used to convert the primary winding voltage Vp (t) of the transformer 130 into the secondary winding voltage Vs (t) of the transformer 130 or convert the secondary winding voltage Vs (t) of the transformer 130 into the primary winding voltage Vp (t) of the transformer 130 with the primary winding number Np: ns, where Np is the primary winding number and Ns is the secondary winding number, and achieve electrical isolation. The converter can be used in a vehicle-mounted charger.
With the development of semiconductor technology, the size of the switching tube is generally small, and the heat dissipation effect is good, so in the isolated DC/DC converter shown in fig. 1, the transformer 130 is the device with the largest size and the largest heat generation amount. It is therefore a current challenge to reduce the volume of the transformer 130 and to ensure that the thermal design meets the requirements.
In view of the above-mentioned problems, in one embodiment of the present application, a transformer is provided, including: a first magnetic core including a first magnetic core portion and at least one second magnetic core portion disposed at an angle to the first magnetic core portion, wherein a cross-sectional area of one of the at least one second magnetic core portion of the first magnetic core is calculated from a magnetic density of the first magnetic core, the magnetic density of the first magnetic core is determined from a heat radiation parameter of the first magnetic core, wherein a primary winding or a secondary winding of a transformer is wound on the first magnetic core;
the second magnetic core comprises a first magnetic core part and at least one second magnetic core part which is arranged at an angle with the first magnetic core part, the at least one second magnetic core part of the second magnetic core is respectively abutted with the at least one second magnetic core part of the first magnetic core, wherein the cross section area of one of the at least one second magnetic core parts of the second magnetic core is obtained according to the magnetic density calculation of the second magnetic core, the magnetic density of the second magnetic core is determined according to the heat dissipation parameter of the second magnetic core, and the second magnetic core is correspondingly wound with a secondary side winding or a primary side winding of a transformer.
Specifically, please refer to a schematic transformer structure of an embodiment of the present application shown in fig. 3. As shown in fig. 3, the transformer 400 includes a first magnetic core 410 and a second magnetic core 420, and as shown in fig. 3, the first magnetic core 410 and the second magnetic core 420 are both E-shaped magnetic cores, and of course, may be other magnetic cores, such as U-shaped magnetic cores, and the collective shape of the magnetic cores is not limited in the present application.
As shown in fig. 3, each of the first and second magnetic cores 410 and 420 includes a first magnetic core portion and at least one second magnetic core portion disposed at an angle to the first magnetic core portion. The first magnetic core 410 includes a first magnetic core portion 411 and at least one second magnetic core portion disposed at an angle to the first magnetic core portion 411. Taking E-type magnetism as an example, the second core portion includes two side posts 412 and 413 and a center post 414, and the second core portion is disposed at an angle to the first core portion 411, as shown in fig. 3, at ninety degrees.
Likewise, the second magnetic core 420 also includes a first magnetic core portion 421 and at least one second magnetic core portion disposed at an angle to the first magnetic core portion 421. Taking E-type magnetism as an example, the second core portion includes two side legs 422 and 423 and a center leg 424, and the second core portion is disposed at an angle to the first core portion 421, as shown in fig. 3, at ninety degrees.
Referring to fig. 3 again, at least one second core portion of the second magnetic core 420 is in contact with at least one second core portion of the first magnetic core 410, as shown in fig. 3, the second core portion 412 is in contact with the second core portion 422, the second core portion 413 is in contact with the second core portion 423, and the second core portion 414 is in contact with the second core portion 424.
Wherein a cross-sectional area of one of the at least one second magnetic core portions of the first magnetic core 410 is calculated from a magnetic density Bp of the first magnetic core 410, wherein the magnetic density Bp of the first magnetic core 410 is determined from a heat dissipation parameter of the first magnetic core 410; the cross-sectional area of one of the at least one second core portion of the second magnetic core 420 is calculated from the magnetic density Bs of the second magnetic core 420, wherein the magnetic density Bs of the second magnetic core 420 is determined according to the heat dissipation parameter of the second magnetic core 420.
That is, the cross-sectional areas of the second core portions of the first and second cores 410 and 420 of the transformer 400 are separately designed such that the utilization rates of the first and second cores 410 and 420 are both improved, thereby optimizing the volume of the transformer 400.
In the prior art, the first magnetic core 410 and the second magnetic core 420 of the transformer 400 are designed identically, i.e. the shapes are identical, the cross sections of the second magnetic core portions of the magnetic cores are identical, and in order to meet the requirement of thermal design, only a larger cross section of the second magnetic core portion can be selected, which may result in low utilization rate of one of the magnetic cores, and thus a large volume of the transformer. If the cross-sectional area of the leg in the first magnetic core 410 is 1 square centimeter to meet the performance requirement of the transformer, and the cross-sectional area of the leg in the second magnetic core 420 is 1.5 square centimeters to meet the performance requirement of the transformer, the cross-sectional area of the leg in the practical application needs to be 1.5 square centimeters, which results in low utilization of the first magnetic core 410.
The first and second magnetic cores 410 and 420 of the present application are separately designed, so that the utilization ratio of the first and second magnetic cores 410 and 420 can be optimized. The inventor researches that the actually needed cross-sectional area of the magnetic core is related to the magnetic density of the magnetic core, and the magnetic density is related to the heat dissipation condition of the magnetic core. When the transformer is used for actual products, the heat dissipation conditions of the primary winding magnetic core of the transformer and the secondary winding magnetic core of the transformer are often different, such as half of the heat dissipation conditions are better and half of the heat dissipation conditions are worse.
Referring to fig. 4, as shown in fig. 4, a transformer 400 shown in fig. 3 is disposed on a PCB 300, and the PCB 300 includes a first surface 310, wherein electronic devices such as an electronic device 311 may be disposed on the first surface 310, and electronic devices such as an electronic device 312 may be disposed on a second surface opposite to the first surface 310, and the electronic devices 311 and 312 are used to perform a power conversion function together with the transformer 400. Of course, the electronic device may be disposed only on the first surface 310, or only on the second surface 310, which is not limited by the present application.
And as shown in fig. 4, the first core part 411 of the first magnetic core 410 is disposed on the first face 310 of the PCB board 300 such that at least one second core part (412 to 414) of the first magnetic core 410 protrudes in a direction away from the first face 310 of the PCB board 300. As shown in fig. 3, at least one second core portion (412-414) distal from the first core 410 extends outwardly at an angle to the first face 310 of the PCB 300, such as ninety degrees from the first face 310 of the PCB 300. Since at least one second core portion of the second magnetic core 420 is respectively abutted with at least one second core portion of the first magnetic core 410, the second magnetic core 420 is further away from the first surface 310 of the PCB 300.
As shown in fig. 4, the first magnetic core 410 is close to the PCB 300, and the second magnetic core 420 is far from the PCB 300, and therefore, the heat dissipation is better. The heat dissipation condition of the primary winding and the secondary winding of the transformer in the actual converter is utilized to determine the respective magnetic densities, and then the cross sectional area of one of the respective second magnetic core parts is obtained according to the respective magnetic densities, so that the cross sectional area of the magnetic cores can be optimally designed, the window width of the winding is optimally designed, and when the number of turns of the winding is determined, the length of the second magnetic core parts can be optimally designed, and the volume of the transformer is optimally designed.
The cross-sectional area of the second core portion of the first magnetic core 410 calculated from the actually determined magnetic density may be the same as the cross-sectional area of the second core portion of the second magnetic core 420, as shown in fig. 3, the cross-sectional area Aes of the center pillar 424 is equal to the cross-sectional area Aep of the center pillar 414. The winding window width of the first magnetic core 410 is equal to the winding window width of the second magnetic core 420.
In one embodiment, the cross-sectional area of the second core portion of the first magnetic core 410 is different from the cross-sectional area of the second core portion of the second magnetic core 420 according to the actually determined magnetic density, as shown in the transformer schematic diagram of another embodiment of the present application in fig. 5, and the cross-sectional area ae of the middle pillar 424 is smaller than the cross-sectional area Aep of the middle pillar 414. The width of the winding window of the second magnetic core 420 is larger than that of the first magnetic core 410, so that the number of winding turns of each layer in the winding window of the second magnetic core 420 is increased, and the number of winding layers can be reduced under the condition of fixed turns, so that the height of the second magnetic core 420 can be reduced, as shown in fig. 5, the height h2 of the second magnetic core 420 is smaller than the height h1 of the first magnetic core 410, and therefore, compared with the prior art adopting the first magnetic core 410 as shown in fig. 4, the volume of the transformer can be reduced on the basis of meeting the performance and the thermal design of the transformer.
The inventor researches and discovers that the heat dissipation condition of the magnetic core is poor, and the magnetic density of the magnetic core needs to be properly reduced. For the power conversion device shown in fig. 4, since the first magnetic core 410 is close to the PCB 300 and the heat dissipation condition is poor, and the second magnetic core 420 is far away from the PCB 300 and the heat dissipation condition is good, the magnetic density of the first magnetic core 410 is preferably smaller than that of the second magnetic core 420. In practical applications, one of the first magnetic core 410 and the second magnetic core 420 may have a magnetic density smaller than that of the other according to actual product conditions.
The heat dissipation parameters mentioned herein are determined according to the heat dissipation condition of the magnetic core, such as the heat conduction path of the magnetic core, etc.
In contrast to the prior art in which the first magnetic core 410 and the second magnetic core 420 are both disposed parallel to the PCB 300, a power conversion apparatus according to the prior art is shown in fig. 6. According to the power conversion device shown in fig. 4, the first magnetic core part 411 of the first magnetic core 410 plays a role in shielding the leakage flux of the transformer winding, so that the interference of the leakage flux of the transformer winding on electronic devices and circuits on the PCB 300 can be reduced, and the performance of the power conversion device can be improved.
The above-mentioned example is that the first magnetic core 410 is close to the PCB 300, and the second magnetic core 420 is far away from the PCB 300, so that the heat dissipation parameters of the first magnetic core 410 and the second magnetic core 420 are different. In practical applications, the heat dissipation parameters of the first magnetic core 410 and the second magnetic core 420 of the transformer may be different due to other reasons, and the application is not limited to the reasons for the different heat dissipation parameters.
In one embodiment, when the primary winding r1 of the transformer is wound on the first magnetic core 410 and the secondary winding r2 of the transformer is wound on the second magnetic core 420, the formula is givenCalculating a cross-sectional area of one of the at least one second core portions of the first magnetic core 410, wherein Vp (t) is a voltage applied to the primary winding r1 (or 450) of the transformer, np is a number of turns of the primary winding r1 (or 450), bp is a magnetic density of the first magnetic core 410, aep is a cross-sectional area of one of the at least one second core portions of the first magnetic core 410, and Aep is a cross-sectional area of the center leg 413 as shown in fig. 3. And according to the formula->The cross-sectional area of one of the at least one second core portion of the second magnetic core 420 is calculated, where Vs (t) is the voltage applied to the secondary winding r1 (or 440) of the transformer, ns is the number of turns of the secondary winding r1 (or 440), bs is the magnetic density of the second magnetic core 420, aes is the cross-sectional area of one of the at least one second core portion of the second magnetic core 420, and Aes is the cross-sectional area of the center leg 423 as shown in fig. 3.
When the primary winding r1 of the transformer is wound on the second core 420, the secondary winding r2 of the transformer is wound on the first core 410 according to the formulaThe cross-sectional area of one of the at least one second core portion of the second magnetic core 420 is calculated, where Vp (t) is the voltage applied to the primary winding r1 of the transformer, np is the number of turns of the primary winding r1, bp is the magnetic density of the second magnetic core 420, and Aep is the cross-sectional area of one of the at least one second core portion of the second magnetic core 420. And according to the formula- >The cross-sectional area of one of the at least one second core portions of the first magnetic core 410 is calculated, where Vs (t) is the voltage applied to the secondary winding r2 of the transformer, ns is the number of turns of the secondary winding r2, bs is the magnetic density of the first magnetic core 410, and Aes is the cross-sectional area of one of the at least one second core portions of the first magnetic core 410.
As described above, the cross-sectional area of one of the second core portions is related to the magnetic density of the magnetic core, the voltage applied to the winding wound around the magnetic core, and the number of turns of the winding. Therefore, in practical applications, the calculated cross-sectional area of one of the second core portions of the two cores may be the same or may be different.
As described above, the cross-sectional area of the center pillar is calculated as an example, and it is needless to say that the cross-sectional area of any one of the second core portions may be calculated as long as the second core portion of the first core for calculating the cross-sectional area and the second core portion of the second core for calculating the cross-sectional area abut against each other. For the E-type magnetic core, the cross-sectional area of the center leg is generally the sum of the cross-sectional areas of the two side legs, and the cross-sectional areas of the two side legs are the same, so that the cross-sectional area of any one group of second magnetic core sections which are abutted against each other can be calculated.
In one embodiment, the isolated DC/DC converter shown in FIG. 1 is a resonant isolated DC/DC converter to improve the performance of the isolated DC/DC converter. With the development of the technology, it is desirable that the transformer 130 is an LLC transformer with integrated leakage inductance, but the leakage inductance of the transformer needs to be increased, which is usually achieved by increasing the physical distance between primary and secondary windings in the prior art, and it is difficult to limit the length, width and height of the transformer.
Referring to fig. 7, fig. 7 is an exploded view of the transformer shown in fig. 3. The transformer 400 further includes an integrally formed magnetic sheet 430, the integrally formed magnetic sheet 430 being disposed between the primary winding and the secondary winding. The integrally formed magnetic sheet 430 as shown in fig. 7 is disposed between a first winding 450 (primary winding or secondary winding) wound on one of the at least one second core portions of the first magnetic core 410 and a second winding 440 (secondary winding or primary winding) wound on one of the at least one second core portions of the second magnetic core 440.
The first magnetic core 410 and the integrally formed magnetic sheet 430 form a semi-closed magnetic loop, and the second magnetic core 440 and the integrally formed magnetic sheet 430 form a semi-closed magnetic loop, and compared with the magnetic path length formed by the first magnetic core 410 and the second magnetic core 440 without adding the integrally formed magnetic sheet 430, the magnetic path length is reduced by half, so that the inductances of the first winding 450 and the second winding 440 are increased, the leakage inductances can be adjusted by adjusting the integrally formed magnetic sheet 430, the adjusted leakage inductances can be used as resonance inductances, and therefore, the additional independent arrangement of resonance inductance windings is not needed, and the physical distance between primary and secondary windings can be reduced, thereby reducing the overall size of the transformer 400.
The integrally formed magnetic sheet 430 is used to integrally assemble the magnetic sheet, so that the assembly is simpler, and the extra loss of the leakage flux cutter housing between the assemblies is avoided.
Referring to fig. 7 again, the first winding 450 and the second winding 440 are annular, and the integrally formed magnetic sheet 430 is also annular, that is, the integrally formed magnetic sheet 430 changes with the shape of the first winding 450 and the second winding 440.
Referring to fig. 8, a schematic diagram of a transformer applied to the power conversion device in fig. 4 according to an embodiment of the present application is shown, at least one of the at least one second core portions of the first magnetic core 410 is provided with a notch 415, and at least one of the at least one second core portions of the second magnetic core 420 is provided with a notch 425. The notch is arranged on the side column, and the notch is used for filling the heat-dissipating glue so that the heat-dissipating glue contacts with the winding wound on the magnetic core and can fully dissipate heat of the winding.
In addition, because the notch arranged on the second magnetic core part can radiate heat to the winding, the opening formed between the magnetic core side posts can be made smaller. As shown in fig. 8, the opening 470 formed between the first leg 412 and the second leg 413 of the first magnetic core 410 may be smaller than a common E-type magnetic core, and the opening 460 formed between the first leg 422 and the second leg 423 of the same second magnetic core 420 may be smaller than a common E-type magnetic core. After the glue is applied, the heat-dissipating glue may fill the openings 460 and 470, and the windings may dissipate heat through the heat-dissipating glue at the openings 460 and 470. Because the openings 460, 470, 415 and 425 can dissipate heat, the openings 460, 470, 415 and 425 can be smaller, so that the exposed area of the windings at each opening can be reduced, the leakage magnetic flux can be reduced, the eddy current loss generated by the leakage magnetic flux on the casing is smaller, and the efficiency of the power conversion device is improved. Meanwhile, the whole exposed area is almost equal to that of a common magnetic core, the heat dissipation effect of the winding is not affected, and the requirement of thermal design is met.
In one embodiment, the opening may be reduced by increasing the distance that the inside of the limb (the side closer to the winding) extends in the direction of the winding. But may be implemented in other ways, as the application is not limited in this respect.
Referring to fig. 7 again, in an embodiment, the first magnetic core 410 includes at least a first sub-magnetic core 4101 and a second sub-magnetic core 4102, and a heat conductive material 480 is disposed between the first sub-magnetic core 4101 and the second sub-magnetic core 4102. Second core 420 includes at least third sub-core 4201 and fourth sub-core 4202, and a thermally conductive material (not shown) is disposed between third sub-core 4201 and fourth sub-core 4202. The magnetic core is divided into at least two halves, and the heat conduction material is added in the middle of the magnetic core, so that heat dissipation can be increased without affecting the magnetic circuit, and loss is reduced.
As shown in fig. 7, the heat conductive material 480 has an L shape, and is partially located between the first sub-core 4101 and the second sub-core 4102, and partially extends along the first core portion of the first core 410. As is the thermally conductive material between third sub-core 4201 and fourth sub-core 4202, which is not described here. One part of the heat conducting material is positioned in the magnetic core, and the other part extends out of the magnetic core, so that the heat in the magnetic core can be carried out, the heat dissipation effect is improved, and the requirement of heat design is met.
In fig. 7, the magnetic core is divided into two halves, and may be divided into any number according to the need in practical application, and the dividing manner may be set according to the need, which is not limited in the present application. The number of the heat conductive materials may be set as required, for example, two in fig. 6, one, or more than two.
In one embodiment, the thermally conductive material 480 is a metal sheet or a ceramic sheet, such as a copper sheet.
For the transformer 400 shown in fig. 3, after the first and second magnetic cores 410 and 420 are assembled, glue is generally dispensed between the leg 413 and the leg 423, between the leg 4112 and the leg 422, and between the middle leg 414 and the middle leg 424 to assemble the first and second magnetic cores 410 and 420 together. When glue is dispensed between all the second magnetic core parts, the stress between the second magnetic core parts is possibly uneven due to heat expansion and cold contraction, so that the magnetic core is broken.
In an embodiment of the present application, glue is dispensed between the second core portions of at least one set of the first magnetic cores 410 and the second core portions of the second magnetic cores 420 that are in contact with each other, and no glue is dispensed between the second core portions of at least one set of the first magnetic cores 410 and the second core portions of the second magnetic cores 420 that are in contact with each other. For example, the side posts 413, 423 and 4112, 422 are not glued, the middle post 414, 424 are not glued, or the middle post 414, 424 are not glued, the side posts 413, 423 and 4112, 422 are not glued, so that the problem of uneven stress during expansion and contraction is reduced, and the possibility of cracking the magnetic core is reduced.
As shown in fig. 7, the transformer further includes a bobbin 490, and the first winding 450 and the second winding 440 are wound around the bobbin 490 and then assembled to the center posts of the first magnetic core 410 and the second magnetic core 420. Of course, the skeleton may not be included.
Please refer to fig. 9, which is a schematic diagram of a power conversion apparatus according to another embodiment of the present application. The power conversion device further includes a heat dissipation housing 500, where the heat dissipation housing 500 is covered around the transformer 400, and a heat dissipation glue (not shown) is filled in the heat dissipation housing 500, so that the first core portion 411 of the first magnetic core 410 is disposed on the first surface 310 of the PCB 300. When in assembly, glue is dispensed between the second core portions of the first magnetic core 410 and the second magnetic core portions of the second magnetic core 420, so as to fix the first magnetic core 410 and the second magnetic core 420, and then the first magnetic core and the second magnetic core are placed in the heat dissipation housing 500, and then a glue filling process is performed, so that the heat dissipation glue fills the gaps in the heat dissipation housing 500, such as the openings 460, 470, the gaps 415 and the gaps 425, and the heat dissipation efficiency of the transformer is improved. And as can be seen from fig. 9, the heat dissipation environment of the first magnetic core 410 is generally poor, and the heat dissipation environment of the second magnetic core 420 is good, so by the above-mentioned scheme of separately designing the first magnetic core 410 and the second magnetic core 420, the magnetic densities of the two can be selected to be different, so as to optimize the design of the magnetic core of the transformer.
The first core portion 411 of the first magnetic core 410 is disposed on the first surface 310 of the PCB 300, and the first core portion 411 may or may not be in direct contact with the first surface 310 of the PCB 300.
In an embodiment of the present application, a method for designing a transformer is further provided, and reference may be made to a schematic transformer structure shown in fig. 3. The method comprises the following steps:
providing a primary winding core 410 for winding a primary winding 450 of a transformer, comprising a first core part 411 and at least one second core part 412, 413 and 414 arranged at an angle to the first core part 411, determining a heat dissipation parameter of the primary winding core 410, determining the magnetic density of the primary winding core 410 according to the heat dissipation parameter of the primary winding core 410, and calculating the cross-sectional area of one of the at least one second core part of the primary winding core 410 according to the magnetic density of the primary winding core 410;
a secondary winding core 420 is provided for winding a secondary winding 440 of a transformer, and includes a first core portion 421 and at least one second core portion 422, 423 and 424 disposed at an angle to the first core portion 421, where the at least one second core portion of the secondary winding core 420 is respectively abutted against the at least one second core portion of the primary winding core 410, a heat dissipation parameter of the secondary winding core 420 is determined, a magnetic density of the secondary winding core 420 is determined according to the heat dissipation parameter of the secondary winding core 420, and a cross-sectional area of one of the at least one second core portions of the secondary winding core 420 is calculated according to the magnetic density of the secondary winding core 420.
Such as calculating the cross-sectional area Aep of center post 414 and the cross-sectional area Aes of center post 424. As in the above analysis, the cross-sectional area of the mutually abutting side posts can also be calculated.
In one embodiment, the formula is based onThe cross-sectional area of one of the at least one second core portions of the primary winding core 410 is calculated, where Vp (t) is the voltage applied to the primary winding 450 wound on the primary winding core 410, np is the number of turns of the primary winding 450, bp is the magnetic density of the primary winding core 410, and Aep is the cross-sectional area of one of the at least one second core portions of the primary winding core 410, such as the cross-street area of the center pillar 414. According to the formulaThe cross-sectional area of one of the at least one second core portions of the secondary winding core 420 is calculated, where Vs (t) is the voltage applied to the secondary winding 440 wound on the secondary winding core 420, ns is the number of turns of the secondary winding 440, bs is the magnetic density of the secondary winding core 420, and Aes is the cross-sectional area of one of the at least one second core portions of the secondary winding core 420, such as the cross-street area of the center pillar 424.
In one embodiment, an integrally formed magnetic sheet 430 is further provided, and as can also be combined with fig. 7, the integrally formed magnetic sheet 430 is disposed between a primary winding 450 wound on the primary winding core and a secondary winding 440 wound on the secondary winding core 420.
As described above, the integrally formed magnetic sheet 430 may provide leakage inductance required for the resonant transformer on the basis of reducing the overall size of the transformer 400.
In one embodiment, at least one of the at least one second core portion of the primary winding core 410 is provided with a notch for filling the heat-dissipating glue so that the heat-dissipating glue contacts the primary winding 450 wound on the primary winding core 410; at least one of the second core portions of the secondary winding core 420 is provided with a notch for filling the heat-dissipating glue so that the heat-dissipating glue contacts the secondary winding 440 wound on the secondary winding core 420, as shown in fig. 8. As mentioned above, notches are typically provided in the limb to expose the windings.
On the basis, the openings formed between the magnetic core side columns can be made smaller, the openings and the gaps are made smaller, the exposed area of the winding at each opening can be reduced, the leakage magnetic flux can be reduced, the eddy current loss generated by the leakage magnetic flux on the shell is smaller, and the efficiency of the power supply conversion device is improved. Meanwhile, the whole exposed area is almost equal to that of a common magnetic core, the heat dissipation effect of the winding is not affected, and the requirement of thermal design is met.
In one embodiment, referring to fig. 7, the primary winding core 410 includes at least a first sub-primary winding core 4101 and a second sub-primary winding core 4102, and a metal sheet 480 is disposed between the first sub-primary winding core 4101 and the second sub-primary winding core 4102; the secondary winding core 420 includes at least a third sub-secondary winding core 4201 and a fourth sub-secondary winding core 4202, with a metal sheet disposed between the third sub-secondary winding core 4201 and the fourth sub-secondary winding core 4202. As described above, heat dissipation can be increased without affecting the magnetic circuit, while loss can be reduced.
In a specific embodiment, the method further comprises a dispensing process, wherein the dispensing process dispenses glue between the second magnetic core parts of the primary winding magnetic cores and the second magnetic core parts of the secondary winding magnetic cores which are in butt joint, such as dispensing glue between center posts of the two magnetic cores. As the same as the above, the problem of uneven stress during expansion and contraction is reduced, and the possibility of cracking of the magnetic core is reduced.
Although embodiments of the present application and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the application as defined by the appended claims.
Furthermore, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. It will be readily apparent to those of ordinary skill in the art from this disclosure that processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present application. It is therefore intended that the following appended claims include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.
Claims (16)
1. A transformer, comprising:
a first magnetic core including a first magnetic core portion and at least one second magnetic core portion disposed at an angle to the first magnetic core portion, wherein a cross-sectional area of one of the at least one second magnetic core portion of the first magnetic core is calculated from a magnetic density of the first magnetic core, the magnetic density of the first magnetic core is determined from a heat radiation parameter of the first magnetic core, wherein a primary winding or a secondary winding of a transformer is wound on the first magnetic core;
The second magnetic core comprises a first magnetic core part and at least one second magnetic core part which is arranged at an angle with the first magnetic core part, the at least one second magnetic core part of the second magnetic core is respectively abutted with the at least one second magnetic core part of the first magnetic core, wherein the cross section area of one of the at least one second magnetic core parts of the second magnetic core is obtained according to the magnetic density calculation of the second magnetic core, the magnetic density of the second magnetic core is determined according to the heat dissipation parameter of the second magnetic core, and the second magnetic core is correspondingly wound with a secondary side winding or a primary side winding of a transformer.
2. The transformer according to claim 1, wherein when the primary winding of the transformer is wound on the first core and the secondary winding of the transformer is wound on the second core,
according to the formulaCalculating a cross-sectional area of one of the at least one second core portions of the first magnetic core, wherein Vp (t) is a voltage applied to a primary winding of the transformer, np is a number of primary winding turns, bp is a magnetic density of the first magnetic core, and Aep is a cross-sectional area of one of the at least one second core portions of the first magnetic core;
According to the formulaCalculating a cross-sectional area of one of the at least one second core portions of the second magnetic core, wherein Vs (t) is a voltage applied to a secondary winding of the transformer, ns is a number of secondary winding turns, bs is a magnetic density of the second magnetic core, and Aes is a cross-sectional area of one of the at least one second core portions of the second magnetic core.
3. The transformer according to claim 1, wherein when the secondary winding of the transformer is wound on the first core and the primary winding of the transformer is wound on the second core,
according to the formulaCalculating a cross-sectional area of one of the at least one second core portions of the second magnetic core, wherein Vp (t) is a voltage applied to a primary winding of the transformer, np is a number of primary winding turns, bp is a magnetic density of the second magnetic core, and Aep is a cross-sectional area of one of the at least one second core portions of the second magnetic core;
according to the formulaCalculating a transverse of one of the at least one second core portions of the first magnetic coreThe cross-sectional area, where Vs (t) is the voltage applied to the secondary winding of the transformer, ns is the number of secondary winding turns, bs is the magnetic density of the first core, and Aes is the cross-sectional area of one of the at least one second core portion of the first core.
4. A transformer according to claim 2 or 3, wherein the magnetic density of one of the first and second magnetic cores is less than the magnetic density of the other.
5. The transformer of claim 1, further comprising an integrally formed magnetic piece disposed between the primary winding and the secondary winding.
6. The transformer of claim 1, wherein at least one of the at least one second core portions of the first magnetic core is provided with a gap for filling heat-dissipating glue so that the heat-dissipating glue contacts the primary winding or the secondary winding wound on the first magnetic core;
and a notch is arranged on at least one of the at least one second magnetic core part of the second magnetic core, and the notch is used for filling heat-dissipating glue so as to enable the heat-dissipating glue to be in contact with the secondary winding or the primary winding wound on the second magnetic core.
7. The transformer according to claim 1 or 6, wherein the first magnetic core comprises at least a first sub-magnetic core and a second sub-magnetic core, a thermally conductive material being arranged between the first sub-magnetic core and the second sub-magnetic core;
The second magnetic core at least comprises a third sub-magnetic core and a fourth sub-magnetic core, and a heat conducting material is arranged between the third sub-magnetic core and the fourth sub-magnetic core.
8. The transformer of claim 1, wherein glue is dispensed between the second core portions of at least one set of the first magnetic cores and the second core portions of the second magnetic cores that are in contact with each other, and wherein glue is not dispensed between the second core portions of at least one set of the first magnetic cores and the second core portions of the second magnetic cores that are in contact with each other.
9. The transformer of claim 1, further comprising a heat dissipating housing, wherein the heat dissipating housing is disposed around the transformer, and wherein heat dissipating glue is filled in the heat dissipating housing.
10. A method of designing a transformer, comprising:
providing a primary winding magnetic core, which is used for winding a primary winding of a transformer and comprises a first magnetic core part and at least one second magnetic core part which is arranged at an angle with the first magnetic core part, determining a heat dissipation parameter of the primary winding magnetic core, determining the magnetic density of the primary winding magnetic core according to the heat dissipation parameter of the primary winding magnetic core, and calculating the cross-sectional area of one of the at least one second magnetic core part of the primary winding magnetic core according to the magnetic density of the primary winding magnetic core;
The method comprises the steps of providing a secondary winding magnetic core for winding a secondary winding of a transformer, wherein the secondary winding magnetic core comprises a first magnetic core part and at least one second magnetic core part which is arranged at an angle with the first magnetic core part, the at least one second magnetic core part of the secondary winding magnetic core is respectively abutted with the at least one second magnetic core part of the primary winding magnetic core, determining the heat dissipation parameter of the secondary winding magnetic core, determining the magnetic density of the secondary winding magnetic core according to the heat dissipation parameter of the secondary winding magnetic core, and calculating the cross-sectional area of one of the at least one second magnetic core parts of the secondary winding magnetic core according to the magnetic density of the secondary winding magnetic core.
11. The method of designing a transformer according to claim 10, wherein the formula isCalculating said at least one second of said primary winding coresOne of the core portions has a cross-sectional area where Vp (t) is a voltage applied to a primary winding wound on the primary winding core, np is a number of primary winding turns, bp is a magnetic density of the primary winding core, and Aep is a cross-sectional area of one of the at least one second core portion of the primary winding core;
according to the formulaCalculating a cross-sectional area of one of the at least one second core portions of the secondary winding core, wherein Vs (t) is a voltage applied to a secondary winding wound around the secondary winding core, ns is a number of secondary winding turns, bs is a magnetic density of the secondary winding core, and Aes is a cross-sectional area of one of the at least one second core portions of the secondary winding core.
12. The method of designing a transformer according to claim 10, wherein the second core portion of the first core for calculating the cross-sectional area and the second core portion of the second core for calculating the cross-sectional area are abutted against each other.
13. The method of designing a transformer according to claim 10, further comprising providing an integrally formed magnetic sheet disposed between a primary winding wound on one of the at least one second core portions on the primary winding core and a secondary winding wound on one of the at least one second core portions on the secondary winding core.
14. The method of claim 10, wherein at least one of the at least one second core portions of the primary winding core is provided with a gap for filling heat-dissipating glue so that the heat-dissipating glue contacts the primary winding wound on the primary winding core;
and a notch is arranged on at least one of the at least one second magnetic core parts of the secondary winding magnetic core and is used for filling heat-dissipating glue so that the heat-dissipating glue is in contact with the secondary winding wound on the secondary winding magnetic core.
15. The method of designing a transformer according to claim 10 or 14, wherein the primary winding core comprises at least a first sub-primary winding core and a second sub-primary winding core, a thermally conductive material being arranged between the first sub-primary winding core and the second sub-primary winding core;
the secondary winding magnetic core at least comprises a third secondary winding magnetic core and a fourth secondary winding magnetic core, and a heat conduction material is arranged between the third secondary winding magnetic core and the fourth secondary winding magnetic core.
16. The method of claim 10, further comprising a dispensing process that dispenses between the second core portions of at least one set of the primary winding cores and the second core portions of the secondary winding cores that are in contact with each other, and leaves the second core portions of at least one set of the first cores and the second core portions of the second cores in contact with each other free of dispensing therebetween.
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| CN202310719534.9A CN116580938A (en) | 2023-06-16 | 2023-06-16 | Transformer and design method thereof |
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