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CN-122001181-A - Small-volume isolation module power supply

CN122001181ACN 122001181 ACN122001181 ACN 122001181ACN-122001181-A

Abstract

The application belongs to the technical field of module power supplies, and provides a small-volume isolation module power supply which comprises a shell and a circuit board assembly encapsulated in the shell. The circuit board assembly adopts an isolated open-loop topology and comprises a printed circuit board, and a primary side component, a secondary side component, a transformer, an input pin and an output pin which are arranged on the printed circuit board. The printed circuit board is divided into three parallel partitions, the transformer is a planar transformer using a square annular magnetic core, the primary and secondary windings are integrated around the window of the magnetic core in an annular shape, the voltage-resistant capacity of the primary and secondary windings is effectively enhanced, and the circuit board assembly can be effectively wrapped by pouring sealant, so that the product electric resistance is further improved, and the power module can stably work for a long time under the condition of high isolation voltage.

Inventors

  • MO YUHANG
  • ZHANG JUNJIE
  • LI JING
  • LI GENGWU

Assignees

  • 广州金升阳科技有限公司

Dates

Publication Date
20260508
Application Date
20260104

Claims (15)

  1. 1. A small-volume isolated modular power supply employing an isolated open loop topology, comprising: A housing having a box shape with one side opened; The circuit board assembly comprises a printed circuit board, and a primary side component, a secondary side component, a transformer, an input pin and an output pin which are arranged on the printed circuit board; the printed circuit board is divided into three parallel partitions, comprising a left side region, a right side region and a separation empty region arranged between the left side region and the right side region, wherein a first magnetic core window and a second magnetic core window are arranged in the separation empty region, the transformer is a planar transformer using a square annular magnetic core, a group of opposite sides of the magnetic core penetrate through the first magnetic core window and the second magnetic core window and are arranged on the printed circuit board in a front-back clamping mode, and the center distance between pins of the input pins and the output pins is 20.5+/-0.5 mm; The circuit board assembly is encapsulated in the cavity of the shell, the input pins and the output pins extend from the printed circuit board to the outside of the opening of the shell, and therefore a small-volume module power supply which is applied to a high-voltage working environment of at least 2000V and meets the long-term pressure-resistant requirement is formed.
  2. 2. The small-volume isolated module power supply according to claim 1, wherein the primary winding and the secondary winding of the transformer are in a same-layer tiled layout and are integrated in the printed circuit board in a laminated mode, the primary winding is integrated around the first magnetic core window in an annular mode, and the secondary winding is integrated around the second magnetic core window in an annular mode.
  3. 3. The low-volume isolated module power supply of claim 1, wherein the printed circuit board has a CTI rating of 0, the printed circuit board is a composite printed laminate having at least two plies, primary and secondary windings of a transformer are laid out in layers on the printed circuit board, and a spacing of the primary and secondary windings in the layers is greater than 0.4mm; Or the primary winding and the secondary winding are arranged in a lamination way on the surface layer and the inner layer of the printed circuit board, the distance between the primary winding and the secondary winding on the surface layer of the printed circuit board is more than 5mm, and the distance between the primary winding and the secondary winding in the inner layer of the printed circuit board is more than 0.4mm.
  4. 4. The small-volume isolated module power supply of claim 1, wherein the magnetic core of the transformer is encapsulated with a bare magnetic structure.
  5. 5. The low volume isolated module power supply of claim 1, wherein a potting compound covers over 95% of the outer surface of the circuit board assembly except for the input pins and the output pins.
  6. 6. The low-volume isolated module power supply of claim 1, wherein a pin center-to-center spacing between the input pin and the output pin is 20.32mm.
  7. 7. The low-profile isolated module power supply of claim 1, wherein a left side region of the printed circuit board is provided with a primary component, the input pins and a portion of the primary winding, and a right side region of the printed circuit board is provided with a secondary component, the output pins and a portion of the secondary winding.
  8. 8. The low-volume isolated module power supply of claim 7, wherein the low-volume isolated module power supply comprises, Defining the minimum value of the distance from the primary side component to the two side surfaces of the magnetic core along the horizontal direction and the distance from the primary side component to the upper side surface and the lower side surface of the magnetic core along the vertical direction as a first interval; Defining the minimum value of the distance from the secondary side component to the two side surfaces of the magnetic core along the horizontal direction and the distance from the secondary side component to the upper side surface and the lower side surface of the magnetic core along the vertical direction as a second interval; the sum of the first spacing and the second spacing is greater than 5mm; the distance between the primary side component and the secondary side component is larger than 5mm.
  9. 9. The low volume isolated module power supply of claim 1, wherein a molding thickness of the potting adhesive between the outer surface of the magnetic core and the adjacent inner wall of the housing is at least 0.4mm.
  10. 10. The low volume isolated module power supply of claim 1, wherein the housing is fabricated from a class 0 CTI plastic material and has a wall thickness of 0.9 ± 0.1mm.
  11. 11. The low-volume isolated module power supply of claim 1, wherein the magnetic core is a bare magnet fixedly bonded by a first magnetic sheet and a second magnetic sheet; the first magnetic sheet and the second magnetic sheet penetrate through the front side and the rear side of the printed circuit board to clamp the first magnetic core window and the second magnetic core window to form a closed magnetic circuit; The magnetic core is formed into a square ring shape by combining a first magnetic sheet in a U shape and a second magnetic sheet in a straight shape; or the magnetic core is formed by combining a first magnetic sheet in a shape of a Chinese character 'Yi' and a second magnetic sheet in a shape of a Chinese character 'U'; or the magnetic core is formed by combining the first magnetic sheet and the second magnetic sheet which are both U-shaped; or the magnetic core is formed by combining the first magnetic sheet and the second magnetic sheet which are both L-shaped.
  12. 12. The low volume isolation module power supply of claim 1, wherein the potting operation uses a potting compound having a CTI rating of 0.
  13. 13. The power supply of claim 1, wherein two sets of symmetrically arranged limiting slots are formed in the inner walls of the two sides of the housing along the mounting direction of the circuit board assembly, and when the circuit board assembly is mounted into the housing, two ends of the circuit board assembly are constrained in the limiting slots.
  14. 14. The low-volume isolated module power supply of claim 1, wherein the bottom of the inner cavity of the housing is configured with at least two limit bosses; after the circuit board assembly is installed and enters the shell, the bottom end of the circuit board assembly is abutted with the limiting boss, so that the circuit board assembly cannot be in direct contact with the bottom of the inner cavity of the shell.
  15. 15. The low-volume isolated module power supply of claim 1, wherein the low-volume isolated module power supply comprises, Two groups of supporting steps with the same height are constructed on the top end face of the opening side of the shell, the two groups of supporting steps are of asymmetric designs with different extension widths, and an inward sunk identification notch is constructed at the top angle of the bottom of one outer side of the shell.

Description

Small-volume isolation module power supply Technical Field The application belongs to the technical field of module power supplies, and particularly relates to a small-volume isolation module power supply. Background With the rapid development of the global new energy industry, the photovoltaic system is used as a core carrier for clean energy utilization, the technology upgrading iteration is continuously advanced, and the direct current 2000V photovoltaic system gradually becomes the main trend of industry because the system current, the wire and equipment loss and the transmission efficiency and the overall cost can be effectively reduced. The module power supply is used as a key component in the photovoltaic system, and the voltage-resistant grade, reliability and volume compatibility of the module power supply directly influence the running stability and economy of the whole photovoltaic system, so that the small-volume and high-isolation module power supply which is adaptive to a 2000V high-voltage system becomes the core requirement of the current industry. At present, most of module power supplies applied to existing photovoltaic systems adopt a magnetic ring transformer scheme, and the transformer completes winding of windings by enabling enameled wires to pass through magnetic rings for many times through a jig so as to achieve energy conversion and electrical isolation functions. However, the above technical solution only meets the short-term use requirement of the 1500V system through testing, in the winding process of the magnetic ring transformer, the enameled wire needs to rub with the jig for many times, which is easy to cause paint film abrasion, further reduces winding insulation performance, and is easy to break down an insulation layer and burn out devices after long-time working, and is not suitable for the long-term high voltage withstand requirement of the 2000V system, and in order to ensure the creepage distance between the input pins and the output pins in a high voltage scene, the design requirements of high isolation performance and small volume are difficult to balance and compromise. Therefore, developing an isolated module power supply with small volume, high voltage-withstanding stability and high reliability becomes a key technical pain point for solving the power supply requirement of a 2000V photovoltaic system. Disclosure of Invention The application provides a small-volume isolation module power supply, which aims to solve the problem that the voltage resistance and stability of the existing photovoltaic system small-volume power supply product are insufficient under the long-term high-voltage working condition. In one aspect, a small-volume isolated modular power supply employing an isolated open loop topology includes a housing having a box-like opening at one side and a circuit board assembly potted in a cavity of the housing. The circuit board assembly comprises a printed circuit board, and a primary side component, a secondary side component, a transformer, an input pin and an output pin which are arranged on the printed circuit board. The printed circuit board is divided into three parallel partitions, including a left side area, a right side area and a separation empty area arranged between the left side area and the right side area, a first magnetic core window and a second magnetic core window are arranged in the separation empty area, the transformer is a planar transformer using square annular magnetic cores, a group of opposite sides of the magnetic cores penetrate through the first magnetic core window and the second magnetic core window and are arranged on the printed circuit board in a front-back clamping mode, input pins and output pins extend to the outside of an opening of a shell from the same side of the printed circuit board, the pin center distance between the input pins and the output pins is 20.5+/-0.5 mm, and the small-volume isolation module power supply is applied to a high-voltage working environment of at least 2000V and is suitable for the long-term pressure-resistant use requirement of a 2000V high-voltage photovoltaic system. Furthermore, the primary winding and the secondary winding of the transformer are in the form of same-layer flat layout and are integrated in the printed circuit board in a laminated mode, the primary winding is integrated around the first magnetic core window in an annular mode, and the secondary winding is integrated around the second magnetic core window in an annular mode. In one scheme, the CTI grade of the printed circuit board is 0 grade, the printed circuit board is a composite printed laminate with at least two layers, the primary winding and the secondary winding are arranged in a lamination mode in the inner layer of the printed circuit board, the distance between the primary winding and the secondary winding in the inner layer of the printed circuit board is larger than 0.4mm, or the primary winding and th