WO2021103556A1 - Integrated transformer and vehicle-mounted charger having integrated transformer - Google Patents

Abstract

Disclosed by the present utility model are an integrated transformer and a vehicle-mounted charger that has the integrated transformer. The integrated transformer comprises: a transformer body that consists of a magnetic core group and a coil group. The transformer body has at least one surface on which a magnetic sheet made from a magnetic material is mounted. The transformer body is mounted in a metal frame, and the metal frame comprises: a bottom plate that supports the transformer body and at least one side plate fixed on the bottom plate, wherein the side plate encloses the outer side of the transformer body. According to the present utility model, by means of designing and forming a shielding structure, the magnetic leakage of the transformer is greatly reduced and magnetic field interference is significantly lowered, which ensures the normal operations of a circuit.

Description

Integrated transformer and vehicle-mounted charger with the integrated transformer Technical field

The utility model relates to the technical field of transformers, in particular to an integrated transformer with a magnetic shielding structure design and a vehicle-mounted charger with the integrated transformer.

Background technique

With the demand for energy saving, emission reduction and air pollution control, new energy vehicles are gradually being commercialized in the market, and electric vehicles are the main force of new energy vehicles. At present, the market has higher and higher requirements for the cost of the entire vehicle, and there is an increasing demand for on-board components. The requirements for volume and weight are gradually increasing. Therefore, low-cost, small-volume, and light-weight vehicle-mounted chargers are a trend.

The transformer used in the existing vehicle charger has a magnetic core group and a coil group. There is no effective magnetic shielding structure on the outside of the transformer. The top, bottom and surroundings of the transformer have a large leakage of magnetic field, and there is serious magnetic field interference, which affects the circuit. Normal work, and will cause EMC problems.

Utility model content

In order to solve the defects such as magnetic leakage in the prior art, the present utility model proposes an integrated transformer with a magnetic shielding structure design and an on-board charger with the integrated transformer. The integrated transformer is designed to form a shielding structure while effectively helping the transformer to dissipate heat. .

The technical scheme adopted by the utility model is to design an integrated transformer, which includes a transformer body composed of a magnetic core group and a coil group, and a magnetic sheet made of magnetic material is installed on at least one side of the transformer body.

Preferably, at the top and/or bottom of the transformer body, there is a leakage magnetic field concentration area that exposes the coil assembly, and at least one leakage magnetic field concentration area is shielded by a magnetic sheet.

Preferably, the transformer body is installed in a metal frame, and the metal frame includes a bottom plate supporting the transformer body and at least one side plate fixed on the bottom plate, and the side plate surrounds the transformer body.

Preferably, the magnetic leakage concentrated part at the bottom of the transformer body is shielded by the bottom plate, and the magnetic leakage concentrated part at the top of the transformer body is shielded by a magnetic sheet.

Preferably, the outer surface of the transformer body is in contact with the side plate to dissipate heat, and the bottom surface of the transformer body is in contact with the bottom plate to dissipate heat.

Preferably, the magnetic leakage concentrated part is provided with two installation grooves at opposite positions. One end of the installation groove is an open end that penetrates the side of the transformer body, and the other end is a closed end. The magnetic sheet is inserted from the open end of the installation groove to the The closed end abuts.

Preferably, the inner walls on both sides of the magnetic flux leakage concentrated portion are recessed to form two mounting grooves, and the side walls of the mounting grooves are provided with limit pieces for pressing the magnetic sheet in the mounting grooves.

Preferably, the metal frame is die-casted with aluminum alloy containing iron elements.

The utility model also proposes a vehicle-mounted charger, which includes the above-mentioned integrated transformer.

Compared with the prior art, the utility model has the following advantages:

1. Install a magnetic sheet on at least one side of the transformer body, and almost all the leakage flux on the transformer body will go from the magnetic sheet, which greatly reduces the leakage magnetic phenomenon of the transformer;

2. A metal frame is arranged on the outside of the transformer body, and the metal frame can effectively reduce the magnetic leakage around and under the transformer;

3. The two sides and bottom surface of the transformer body are in contact with the metal frame, which is conducive to the rapid heat dissipation of the transformer.

Description of the drawings

The present utility model will be described in detail below in conjunction with embodiments and drawings, in which:

Figure 1 is a structural schematic diagram of the utility model without a magnetic sheet on the transformer body;

Figure 2 is a structural schematic diagram of the transformer body in the utility model installed in a metal frame;

Fig. 3 is a schematic diagram of the structure of the transformer body equipped with a magnetic sheet in the utility model.

Detailed ways

In order to make the technical problems, technical solutions and beneficial effects to be solved by the present utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described here are only used to explain the present utility model, and are not used to limit the present utility model.

It should be noted that when an element is referred to as being "fixed to" or "disposed on" another element, it can be directly on the other element or indirectly on the other element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or indirectly connected to the other element.

In the description of the present utility model, it should be understood that the terms "center", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", The orientation or positional relationship indicated by "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. is the relative positional relationship between elements or based on the drawings shown The orientation is only for the convenience of describing the utility model and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation of the utility model.

In the description of the present utility model, it should be noted that, unless otherwise clearly specified and limited, the terms "installation", "connection", and "connection" should be understood in a broad sense. For example, it can be a fixed connection or an optional connection. Detachable connection, or integral connection; it can be mechanical connection or electrical connection; it can be directly connected or indirectly connected through an intermediate medium, it can be the internal communication of two elements or the interaction relationship between two elements. For those of ordinary skill in the art, the specific meaning of the above-mentioned terms in the present utility model can be understood according to specific circumstances.

It should be noted that, for ease of description, the drawings only show part of the structure related to the present invention, but not all of the structure.

As shown in Figures 1 to 3, the integrated transformer proposed by the present invention includes: a transformer body 1 composed of a winding bracket 13, a coil set 12 and a magnetic core set 11. The coil set 12 includes two coils, one coil is wound At one end of the winding support 13, another coil is wound on the other end of the winding support 13. The specific structure of the transformer body is as follows, the magnetic core group 11 is composed of two left and right magnetic cores spliced together, and the magnetic core and the winding support 13 are installed Fixed, the center of the winding bracket 13 is provided with a mounting hole, and the magnetic core is provided with a mounting post which is inserted and matched with the mounting hole. The outer diameter of the mounting post and the inner diameter of the mounting hole are in clearance fit, and the mounting post of a magnetic core starts from the mounting hole. Insert one end of the magnetic core, and insert the mounting post of the other magnetic core from the other end of the mounting hole. The shape of the mounting post and the mounting hole is not limited. Of course, in practical applications, in order to reinforce the structure of the transformer body 1, the splicing surface of the two magnetic cores is provided with a plug-in structure. In more detail, a number of protrusions are provided on the splicing surface of one magnetic core, and the splicing of the other magnetic core A number of concave holes corresponding to the convex pillars are arranged on the surface. The convex pillars and the concave holes can adopt interference fit to fix the two magnetic cores. The insertion ends of the convex pillars are provided with guiding surfaces to facilitate insertion into the concave holes.

The transformer body is equipped with a magnetic sheet 14 on at least one side of the transformer body. The magnetic sheet 14 is made of magnetic material. The magnetic permeability of the magnetic material is much higher than that of air. Therefore, the leakage magnetic field is almost completely removed from the shielding magnetic sheet. The material of the magnetic sheet 14 Made of magnetic material, the magnetic circuit is continuous and smooth, which is beneficial to guide all the leakage flux of the transformer body to pass through the magnetic sheet 14. Because the magnetic sheet 14 has a large resistivity, the eddy current loss on the magnetic sheet 14 is very small, which improves The efficiency of the whole machine.

Based on the existing installation structure of the transformer body 1, the top and bottom of the transformer body 1 have magnetic leakage concentrated parts that expose the coil assembly 12, and at least one magnetic leakage concentrated part is covered by the magnetic sheet 14 to reduce the magnetic leakage phenomenon.

Preferably, the transformer body 1 is installed in a metal frame 2. The metal frame 2 includes a bottom plate 21 and at least one side plate 22 fixed on the bottom plate 21. The bottom plate 21 supports the transformer body 1, and the side plate 22 surrounds the transformer body 1. Outside, the magnetic leakage concentrated area on the top of the transformer body 1 is covered by the magnetic sheet 14, the magnetic leakage at the bottom and surroundings of the transformer body 1 is shielded by the metal frame 2, and the magnetic leakage on the top of the transformer body 1 is shielded by the magnetic sheet 14. The metal frame 2 is made of aluminum alloy die-casting. Since die-cast aluminum has a certain proportion of iron content, the magnetic resistance on the magnetic circuit is much smaller than air, which can effectively prevent the leakage of the magnetic field at the bottom and around the transformer body 1, and because aluminum alloy is Good conductor, and the magnetic leakage of the transformer body 1 is a high-frequency magnetic field, so the eddy current generated on the aluminum alloy die casting also consumes the energy of the magnetic leakage and reduces the magnetic leakage interference.

As shown in Figures 2 and 3, in a preferred embodiment, the bottom plate 21 is provided with two opposite side plates 22, the two side plates 22 are parallel to each other, and the transformer body 1 is inserted into the two sides from the top of the metal frame 2. Between the plates 22, the two outer sides of the transformer body 1 are in contact with the side plate 22 on the side to dissipate heat, and the bottom surface of the transformer body 1 is in contact with the bottom plate 21 to dissipate heat. Since the bottom plate 21 and the side plates 22 are made of metal materials, it has With good thermal conductivity, the transformer body 1 utilizes the metal frame 2 to transfer heat to the outside, so as to achieve the effect of rapid heat dissipation. In practical applications, thermally conductive glue can be set between the outer side of the transformer body 1 and the side plates 22, and between the bottom surface of the transformer body 1 and the bottom plate 21, and the gap between the transformer body 1 and the metal frame 2 can be filled with the thermally conductive glue. In order to effectively improve the thermal efficiency.

After the utility model designs the metal frame 2 and the magnetic sheet 14, the magnetic leakage of the transformer body 1 is effectively shielded, the magnetic field interference is significantly reduced, and the normal operation of the circuit is ensured. Moreover, the metal frame 2 can assist the transformer body 1 to dissipate heat, and the magnetic sheet Joining will hardly affect the efficiency of the whole machine.

The installation structure of the magnetic sheet 14 is as follows. The magnetic leakage concentrated part is provided with two installation grooves 111 in opposite positions. One end of the installation groove 111 is an open end that penetrates the side of the transformer body 1 and the other end is a closed end. The open end of the groove 111 is inserted to abut against the closed end. In more detail, the inner walls on both sides of the magnetic leakage concentrated part are recessed to form two mounting grooves 111, and the side wall of the mounting groove 111 is provided with a limiting piece 112 that presses the magnetic sheet 14 into the mounting groove 111 to For example, the magnetic sheet 14 is arranged at the magnetic leakage concentrated part on the top of the transformer body 1. The two sides of the top of the magnetic leakage concentrated part are recessed to form two mounting grooves 111. The positioning piece 112, after the magnetic piece 14 is inserted into the mounting groove 111, the limiting piece 112 presses the magnetic piece 14 down in the mounting groove 111.

In a preferred embodiment, during installation, after aligning the side where the open end of the mounting groove 111 is located with the side plate 22, the transformer body 1 is placed downwards into the metal frame 2, and the side plate 22 is blocked in the mounting groove 111 To prevent the magnetic sheet 14 in the mounting groove 111 from being swayed out of the transformer body 1 by external force, so as to improve the structural stability.

The utility model also proposes a vehicle-mounted charger, including the above-mentioned integrated transformer. Through the shielding structure design of the integrated transformer, the interference of the transformer leakage magnetic field on the normal circuit and EMC problems can be solved at a low cost, so that the vehicle-mounted charger has low cost, The advantages of small size, light weight and high performance.

The above descriptions are only preferred embodiments of the present utility model, and are not intended to limit the present utility model. Any modification, equivalent replacement and improvement made within the spirit and principle of the present utility model shall be included in this utility model. Within the scope of protection of utility models.

Claims (9)

1. An integrated transformer includes a transformer body composed of a magnetic core group and a coil group. The transformer body is characterized in that at least one side of the transformer body is installed with a magnetic sheet made of magnetic material.
2. The integrated transformer according to claim 1, wherein the top and/or bottom of the transformer body has a leakage magnetic field concentration site that exposes the coil assembly, and at least one of the leakage magnetic field concentration site is covered by the magnetic field.片Shield.
3. The integrated transformer of claim 2, wherein the transformer body is installed in a metal frame, the metal frame comprising: a bottom plate supporting the transformer body and at least one side plate fixed on the bottom plate, The side plate is arranged on the outer side of the transformer body.
4. The integrated transformer according to claim 3, wherein the magnetic leakage concentrated part at the bottom of the transformer body is covered by the bottom plate, and the magnetic leakage concentrated part at the top of the transformer body is shielded by the magnetic sheet.
5. The integrated transformer of claim 3, wherein the outer side surface of the transformer body contacts the side plate to dissipate heat, and the bottom surface of the transformer body contacts the bottom plate to dissipate heat.
6. The integrated transformer according to any one of claims 2 to 5, wherein the magnetic leakage concentrated part is provided with two installation grooves in opposite positions, and one end of the installation groove is through the side surface of the transformer body. The open end and the other end are closed ends, and the magnet piece is inserted from the open end of the mounting groove to abut against the closed end.
7. The integrated transformer according to claim 6, wherein the inner walls on both sides of the leakage flux concentration portion are recessed to form two mounting grooves, and the side walls of the mounting grooves are provided with the magnetic sheet The limit piece pressed in the mounting groove.
8. The integrated transformer of claim 1, wherein the metal frame is die-casted with aluminum alloy containing iron elements.
9. A vehicle-mounted charger, characterized by comprising: the integrated transformer according to any one of claims 1 to 8.

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