CN219143933U

CN219143933U - Transformer framework and flat line LLC transformer suitable for low-voltage heavy current

Info

Publication number: CN219143933U
Application number: CN202223353968.1U
Authority: CN
Inventors: 王刚; 郝山; 王磊; 杨国斌; 程志勇
Original assignee: Mornsun Guangzhou Science and Technology Ltd
Current assignee: Mornsun Guangzhou Science and Technology Ltd
Priority date: 2022-12-14
Filing date: 2022-12-14
Publication date: 2023-06-06
Anticipated expiration: 2032-12-14

Abstract

The utility model discloses a transformer framework and a flat line LLC transformer suitable for low-voltage high current, wherein the transformer framework comprises a winding post and baffle plates arranged at two ends of the winding post, the upper end and the lower end of each baffle plate respectively extend out of supporting legs, and the distance from the end surface of each supporting leg to the winding post is larger than the winding height of a primary winding. The baffle plate is provided with the supporting feet, so that the transformer is supported and raised, and the distance from the end surface of the supporting feet to the winding column is larger than the winding height, so that a certain gap is formed between the winding and the bottom of the transformer, and an air channel is formed, thereby being beneficial to heat dissipation.

Description

Transformer framework and flat line LLC transformer suitable for low-voltage heavy current

Technical Field

The utility model relates to a transformer framework, and also relates to a flat line LLC transformer using the transformer framework and suitable for low-voltage high-current.

Background

The transformer is a device for changing alternating voltage by utilizing the principle of electromagnetic induction, and the main components of the transformer are a primary winding, a secondary winding, a magnetic core, a transformer framework and the like, wherein the transformer framework is used as a main body structure of the transformer, and the transformer mainly has the functions of insulation, winding and magnetic core assembly. The conventional transformer frameworks are provided with pin feet, and the size of the transformer frameworks is relatively large. In some transformer designs with strict requirements on size, an independent winding framework without pin needles is often adopted to optimize the volume of the transformer, and the framework is more common in the market at present, as shown in fig. 1, and comprises a middle column 1 and two circular baffles 2, so that the winding of the framework without pin needles is realized, and the volume of the transformer is optimized to a certain extent; disadvantages are: 1. the design of no wire outlet slot is adopted, the winding inlet wire can be completely bent inside the wire outlet slot, the wire outlet space is reduced, and the difficulty of producing wire outlet is high; 2. the design of no supporting surface is realized, the coil is directly flatly attached to the bottom, no air channel is arranged, and heat dissipation is not facilitated.

In addition, with the development of electronic technology, power supply products are always developed towards high power density and small volume, and the LLC topology is a common soft switching topology for high-power supplies, and the design modes of the LLC transformers in common use at present mainly include the following 3 kinds:

(1) And the design of leakage inductance is integrated, skeleton type inductors of the left and right grooves are formed, and the secondary side adopts a litz wire mode. The low-power and low-current power supply has the advantages that the low-power and low-current power supply is suitable for outputting occasions, and external resonance inductance is saved; disadvantages are: (1) when the power and the current are increased, the thicker multi-strand litz wire can seriously influence the production assembly efficiency, and the production difficulty is high. (2) When the power and the current are increased, the volume of the transformer is increased, the leakage inductance is increased, and the transformer is not suitable for the parameter design of a high-power transformer.

(2) The design of external leakage inductance, the main transformer adopts a common sandwich winding method, and the secondary side adopts a litz wire mode. The high-power transformer has the advantages that the external resonant inductor is good in inductance design, and is suitable for high-power transformer parameter design: disadvantages are: (1) when the power and the current are increased, the thicker multi-strand litz wire can seriously influence the production assembly efficiency, and the production difficulty is high. (2) Inductance increases cost, PCB space and volume.

According to the design of the external leakage inductance, the primary side of the main transformer adopts a wire cake, and the secondary side adopts a copper sheet or flat wire design mode. The advantages are that: (1) the external resonant inductor has good inductance design and is suitable for the parameter design of the high-power transformer. (2) The secondary side adopts copper sheet or flat line design, optimizes the transformer volume, improves production efficiency. Disadvantages are: (1) the external inductance increases cost, PCB space and volume. (2) The primary side adopts a wire cake design, and has larger eddy current effect with the flat coil or copper sheet of the secondary side, and under the same wire diameter condition, the temperature rise of the actual test transformer is much higher.

Disclosure of Invention

The first object of the present utility model is to provide a transformer skeleton with simple structure, low cost and heat dissipation.

The first object of the utility model is achieved by the following technical measures: the utility model provides a transformer skeleton, its characterized in that includes wrapping post and locates the baffle at wrapping post both ends, the supporting legs is stretched out respectively to upper end and the lower extreme of baffle, the terminal surface of supporting legs is greater than primary winding wire winding height to the distance of wrapping post.

The baffle plate is provided with the supporting feet, so that the transformer is supported and raised, and the distance from the end surface of the supporting feet to the winding column is larger than the winding height, so that a certain gap is formed between the winding and the bottom of the transformer, and an air channel is formed, thereby being beneficial to heat dissipation.

The utility model is characterized in that notch-shaped wire outlet grooves are formed on the supporting legs at the upper end and the supporting legs at the lower end. According to the design of the wire outlet slot, the winding inlet and outlet wires directly go out of the wire outlet slot and cannot be bent inside the wire outlet slot, so that the utilization rate of the wire outlet slot is improved, the internal wire outlet space is optimized, and the volume of the transformer is reduced.

The transformer framework is of a vertically-and-horizontally symmetrical structure, the upper end supporting leg and the lower end supporting leg of each baffle are respectively provided with a wire outlet groove, the wire outlet grooves of the two baffles on the upper end supporting leg correspond to each other in left and right, and the wire outlet grooves on the lower end supporting leg correspond to each other in left and right. The winding inlet and outlet wires can be led out from any wire outlet slot without distinguishing directions, thereby being convenient for operation and improving the production efficiency.

A second object of the present utility model is to provide a flat line LLC transformer suitable for low voltage and high current using the above-described transformer frame.

The second object of the utility model is achieved by the following technical measures: the flat line LLC transformer suitable for low-voltage high current using the transformer framework is characterized by comprising a primary winding, a primary winding framework, a first secondary winding, a second secondary winding, a magnetic core, a bottom plate and insulating paper, wherein the primary winding is wound on the winding post, a middle post of the magnetic core penetrates through the winding post, the first secondary winding and the second secondary winding are respectively inserted into the magnetic core and sleeved on the middle post, the first secondary winding and the second secondary winding are respectively positioned on one side of the baffle, namely symmetrically positioned on two sides of the primary winding, the insulating paper is arranged between the secondary winding and the magnetic core, the bottom plate is arranged below the primary winding framework, and the primary winding and the secondary winding are fixed through bottom plate pin.

The primary winding is a three-layer insulated wire, a horizontal multilayer C-shaped winding method is adopted, the primary winding enters and exits from a lower support leg wire outlet groove close to the primary winding and is fixed by dispensing after being inserted into a primary hole extending to the primary winding along a bottom plate (the design of the primary winding without flying wires is realized).

According to the utility model, the first secondary winding and the second secondary winding are paint-sprayed copper sheets or flat wires, insulation treatment is not required between the copper sheets or the flat wires, each of the first secondary winding and the second secondary winding at least comprises an Ns1 winding and 1 Ns2 winding, and the Ns1 winding and the Ns2 winding are the same in quantity.

According to the transformer, the bottom outlet feet of the first secondary winding and the second secondary winding are provided with the bosses which are inserted into the secondary holes of the bottom plate and fixed by dispensing, and the lower end supporting feet of the primary winding framework are supported on the bottom plate, so that the transformer is supported and the heat dissipation is improved.

The number of windings of the first secondary winding and the second secondary winding is the same, and each secondary winding at least comprises more than two even windings. The secondary windings on each side are symmetrically distributed with at least more than two even windings, so that leakage inductance of the transformer is greatly reduced, and the transformer parameter design of the high-power supply adopting integrated leakage inductance is facilitated.

The magnetic core is formed by butt joint of two half magnetic cores, each half magnetic core is composed of a center pillar, side arms extending from the end parts of the center pillar to two sides, and side walls connected with the side arms, and the side arms gradually widen from the center pillar to the side walls.

Compared with the prior art, the utility model has the following remarkable technical effects:

(1) The baffle plate of the transformer framework is provided with the supporting feet, so that the transformer is supported and elevated, and the distance from the end surface of the supporting feet to the winding column is larger than the winding height, so that a certain gap is formed between the winding and the bottom of the transformer, and an air channel is formed, thereby being beneficial to heat dissipation.

(2) The upper end supporting legs and the lower end supporting legs of the two baffles of the transformer framework are respectively provided with the wire outlet grooves, and the winding inlet and outlet wires can be led out from any wire outlet groove without distinguishing directions, so that the operation is convenient, the production efficiency is improved, the winding inlet and outlet wires can not be bent in the wire outlet grooves, the internal wire outlet space is optimized, and the volume reduction of the transformer is facilitated.

According to the transformer, the secondary flat wire windings are respectively arranged on two sides of the primary winding, at least two even windings are symmetrically distributed on each side, leakage inductance of the transformer is greatly reduced, and the transformer parameter design of the high-power supply adopting integrated leakage inductance is facilitated.

The primary winding of the transformer adopts a horizontal multilayer C-shaped winding method, and flat wire windings are symmetrically arranged on two sides of the secondary winding, so that the magnetic field direction is optimized, the eddy current effect is reduced, the loss is reduced, the temperature rise effect is obviously improved, and the efficiency is better; the position of the magnetic core for opening the air gap is just in the middle of the primary winding framework, so that the influence of leakage inductance heat on the coil and the flat wire is effectively reduced, and the temperature rise is improved.

The secondary winding of the transformer uses thinner flat wires, so that the operation difficulty caused by adopting thicker multi-strand litz wires under the condition of high current is avoided; the primary winding wire is directly fixed from the wire inlet and outlet of the opening at the bottom of the primary framework to the primary side hole of the bottom plate, the whole transformer is designed without flying wires, the appearance is better, and the production operation efficiency is improved.

(6) The transformer can enable design mode parameters of the high-power integrated leakage inductance transformer to be more easily matched, does not need external resonance inductance, and saves cost; the temperature rise effect is good, and under the same power condition, the transformer can realize smaller volume, and the space is optimized.

Drawings

The utility model will now be described in further detail with reference to the drawings and to specific examples.

FIG. 1 is a schematic diagram of a prior art independent pin-free needle bobbin;

FIG. 2 is a schematic view of the structure of the transformer framework of the present utility model;

FIG. 3 is a side view of the transformer of the present utility model;

fig. 4 is a schematic perspective view of a transformer according to the present utility model;

FIG. 5 is a schematic diagram of the secondary winding structure of the transformer of the present utility model;

FIG. 6 is a schematic diagram of an insulating paper structure of a transformer of the present utility model;

FIG. 7 is a schematic diagram of the core structure of the transformer of the present utility model (half core shown);

fig. 8 is a schematic diagram of the structure of the bottom plate of the transformer of the present utility model.

Detailed Description

As shown in fig. 2, the transformer framework 8 is in a structure which is symmetrical up and down and left and right, and comprises a winding post 3 and baffle plates 4 arranged at two ends of the winding post, wherein the winding post 3 is provided with through holes 7, the upper end and the lower end of the baffle plates 4 respectively extend out of supporting legs, and the distance from the end surfaces 5 of the supporting legs to the winding post 3 is larger than the winding height of a primary winding. Notch-shaped outlet grooves 6 for inlet and outlet wires are respectively formed on the support legs at the upper end and the support legs at the lower end. The upper end supporting leg and the lower end supporting leg of each baffle are respectively provided with an

outlet slot

6, 4 outlet slots are arranged in total, the outlet slots on the upper end supporting leg correspond to each other in left and right, and the outlet slots on the lower end supporting leg correspond to each other in left and right.

As shown in fig. 3 to 8, a flat line LLC transformer suitable for low voltage and high current using the above-mentioned transformer frame includes a primary winding, a primary winding frame using the above-mentioned transformer frame, a first secondary winding 9, a second secondary winding 10, a magnetic core 11, a bottom plate 12 and an insulating paper 14, the primary winding is wound on the winding post 3, a middle post 13 of the magnetic core 11 passes through the winding post 3, the first secondary winding 9 and the second secondary winding 10 are respectively inserted into the magnetic core 11 and sleeved on the middle post 13, the first secondary winding 9 and the second secondary winding 10 are respectively located on one side of the baffle 4, i.e. symmetrically located on both sides of the primary winding, the insulating paper 14 is disposed between the secondary winding and the magnetic core, the bottom plate 12 is disposed below the primary winding frame, and the primary winding and the secondary winding are fixed by the bottom plate 12.

The distance from the end surface of the supporting leg of the transformer framework 8 to the winding column 3 is larger than the winding height of the primary winding, so that the transformer can be supported and raised, a certain gap is formed between the transformer coil and the bottom baffle plate, and an air channel 21 is formed, so that the heat dissipation of the transformer is facilitated.

In this embodiment, the primary winding adopts three layers of insulated wires, and is overlapped and wound on the primary winding framework in a horizontal multilayer C-shaped winding method, and the primary winding is fixed by dispensing after being inserted into and out of a wire outlet slot on a lower end supporting leg which is close to the primary winding and extending to a primary hole 15 on the base plate along the base plate.

The first secondary winding 9 and the second secondary winding 10 are paint-sprayed copper sheets or flat wires and are respectively arranged on two sides of the primary framework, each secondary winding at least comprises an Ns1 winding and 1 Ns2 winding, the Ns1 windings and the Ns2 windings are the same in number and are fixed through bottom plate pins at the bottom. The number of windings of the first secondary winding 9 and the second secondary winding 8 is the same, and each secondary winding comprises at least more than two even windings. The bottom of first vice limit winding 9 and second vice limit winding 10 goes out the foot and is equipped with two bosss 16, and boss 16 peg graft in the vice limit hole 17 of bottom plate 12 and the point is glued fixedly, and the supporting leg terminal surface 5 of former limit wire winding skeleton supports on bottom plate 12 this moment for the height of boss and the bottom parallel and level of former limit wire winding skeleton play support and the effect of raising to the transformer.

The maximum diameter of the center column of the magnetic core is smaller than the minimum diameter of the inner side of the primary winding framework. The magnetic core is inserted from the direction of the secondary windings on two sides, so that the cylindrical framework of the primary winding is positioned at the middle position of the whole transformer, and the position of the magnetic core for opening an air gap is just positioned at the bottom of the framework. The magnetic core is formed by butt joint of two halves of magnetic cores, each half of magnetic core 18 is composed of a middle column 13, side arms 19 extending from the end part of the middle column 13 to two sides, and side walls 20 connected with the side arms 19, and the side arms 19 gradually widen from the middle column 13 to the side walls 20.

The bottom plate adopts the PCB base plate design, has offered two primary side holes 15 on the bottom plate, supplies both sides secondary side winding to go out two sets of secondary side holes 17 that the foot is fixed, and every group has three secondary side holes 17, and primary side winding's play foot inserts primary side hole, and secondary side flat line's play foot inserts secondary side hole, then the point is glued fixedly, and wherein primary side winding goes out the foot and secondary side winding goes out the foot between needs to keep certain distance, guarantees to satisfy the safety rule requirement.

The insulating papers 14 are respectively arranged between the secondary winding and the magnetic core, and play a role in preventing the magnetic core and the secondary flat wire from being in direct contact and short circuit. The insulating paper may also be replaced with a PCB baffle or other insulating safety material.

The installation process of the utility model is as follows: the first secondary winding and the second secondary winding are respectively symmetrically arranged at two sides of the primary winding, the magnetic cores of the transformer are inserted into the frameworks along two sides of the secondary winding for assembly, a layer of insulating paper is respectively padded between the magnetic cores at two sides and the secondary winding, the secondary feet can be directly inserted into the positions of corresponding holes of the bottom plate, and the primary winding is required to be led out from the opening at the bottom of the primary framework to be fixed to the positions of the primary holes of the bottom plate.

The embodiments of the present utility model are not limited thereto, and according to the above-described aspects of the present utility model, the present utility model may be modified, replaced or altered in various other ways without departing from the basic technical spirit of the present utility model, all of which fall within the scope of the claims of the present utility model, according to the general technical knowledge and conventional means of the present art.

Claims

1. The utility model provides a transformer skeleton which characterized in that: the winding device comprises a winding post and baffle plates arranged at two ends of the winding post, wherein the upper end and the lower end of each baffle plate respectively extend out of supporting legs, and the distance from the end surface of each supporting leg to the winding post is greater than the winding height of a primary winding.

2. The transformer armature of claim 1, wherein: and notch-shaped wire outlet grooves are formed in the supporting legs at the upper end and the supporting legs at the lower end.

3. The transformer armature of claim 2, wherein: the transformer framework is of an up-down and left-right symmetrical structure, the upper end supporting leg and the lower end supporting leg of each baffle are respectively provided with an outlet slot, the outlet slots of the two baffles on the upper end supporting leg correspond left and right, and the outlet slots on the lower end supporting leg correspond left and right.

4. The flat line LLC transformer suitable for low voltage and high current using the transformer framework according to claims 1-3 is characterized by comprising a primary winding, a primary winding framework, a first secondary winding, a second secondary winding, a magnetic core, a bottom plate and insulating paper, wherein the primary winding is wound on the winding post, a center post of the magnetic core penetrates through the winding post, the first secondary winding and the second secondary winding are respectively inserted into the magnetic core and sleeved on the center post, the first secondary winding and the second secondary winding are respectively positioned on one side of the baffle plate, namely symmetrically positioned on two sides of the primary winding, the insulating paper is arranged between the secondary winding and the magnetic core, the bottom plate is arranged below the primary winding framework, and the primary winding and the secondary winding are fixed through a bottom plate pin.

5. The flat line LLC transformer for low voltage high current as claimed in claim 4, wherein: the primary winding is a three-layer insulated wire and adopts a horizontal multi-layer C-type winding method.

6. The flat line LLC transformer for low voltage and high current as claimed in claim 5, wherein: the primary winding is inserted into and out of a wire outlet groove on a lower end supporting leg close to the primary winding and is fixed by dispensing after being inserted into a primary hole extending to the primary winding along the bottom plate.

7. The flat line LLC transformer for low voltage and high current as claimed in claim 6, wherein: the first secondary winding and the second secondary winding are paint-sprayed copper sheets or flat wires and at least comprise an Ns1 winding and 1 Ns2 winding, and the Ns1 winding and the Ns2 winding are the same in number.

8. The flat line LLC transformer for low voltage high current as claimed in claim 7, wherein: the bottom of first vice limit winding and second vice limit winding goes out the foot and is equipped with the boss, the boss peg graft in the vice side hole of bottom plate and the point is glued fixedly, and the lower extreme supporting leg of former limit wire winding skeleton supports on the bottom plate this moment.

9. The flat line LLC transformer for low voltage and high current as claimed in claim 8, wherein: the first secondary winding and the second secondary winding have the same number of windings, and each secondary winding at least comprises more than two even windings.

10. Flat line LLC transformer suitable for low voltage and high current according to any of the claims 4-9, characterized in that: the magnetic core is formed by butt joint of two half magnetic cores, each half magnetic core comprises a center pillar, side arms extending from the end parts of the center pillar to two sides, and side walls connected with the side arms, and the side arms gradually widen from the center pillar to the side walls.