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CN-224217327-U - Ultrathin high-power LLC resonant main transformer for module power supply

CN224217327UCN 224217327 UCN224217327 UCN 224217327UCN-224217327-U

Abstract

The utility model discloses an ultrathin high-power LLC resonant main transformer for a module power supply, which comprises an ER type wide-temperature low-loss flat magnetic core, a primary side wire cake wound on the magnetic core, a secondary side copper sheet arranged on the magnetic core, wherein the primary side wire cake adopts a special three-layer wire structure, and the secondary side copper sheet is led out through a copper nail to form an SMT mounting pin. The utility model adopts a special ER type flat magnetic core, improves the window utilization rate, reduces the whole volume, adopts a special three-layer wire cake structure on the primary side, improves the insulation performance, meets the safety standard requirement, reduces the conductor loss, improves the heat radiation capacity by adopting an optimally designed copper sheet structure on the secondary side, has a flat integral flat design, is convenient to combine with a radiator on the upper and lower surfaces, improves the heat radiation efficiency, reduces the volume by 1/3-1/2 under the same power condition, and obviously improves the power density.

Inventors

  • LU BENHAO
  • Cen Xiuqiong
  • LUO GUANGMING

Assignees

  • 成都浩宇能创电子科技有限公司

Dates

Publication Date
20260508
Application Date
20250410

Claims (6)

  1. 1. An ultra-thin high-power LLC resonant main transformer for a module power supply, comprising: an ER type wide-temperature low-loss flat magnetic core (1); A primary side wire cake (2) wound on the magnetic core (1); a secondary copper sheet (3) arranged on the magnetic core (1); The primary side line cake (2) adopts a special three-layer line structure; and the secondary copper sheet (3) is led out through a copper nail to form an SMT mounting pin.
  2. 2. The ultra-thin high-power LLC resonant main transformer for a module power supply according to claim 1, wherein the magnetic core (1) is an ER-type flat plate structure having flat upper and lower surfaces.
  3. 3. Ultrathin high-power LLC resonant main transformer for modular power supplies as claimed in claim 1, characterized in that the three-layer structure of the primary-side pancake (2) comprises multiple layers of insulating material around the conductors for enhancing the insulation between primary and secondary sides.
  4. 4. The ultra-thin high-power LLC resonant main transformer for a module power supply according to claim 1, wherein the thickness of the secondary copper sheet (3) is designed according to the magnitude of the output current.
  5. 5. The ultra-thin high-power LLC resonant main transformer for a modular power supply according to claim 1, wherein the volume of the transformer is reduced by 1/3 to 1/2 compared with a conventional transformer of the same power.
  6. 6. The ultra-thin high power LLC resonant main transformer for modular power supplies as claimed in claim 1, wherein said transformer is adapted for power range of 500W to 6 KW.

Description

Ultrathin high-power LLC resonant main transformer for module power supply Technical Field The utility model relates to the technical field of electronic components, in particular to an ultrathin high-power LLC resonant main transformer for a module power supply. Background LLC resonant topology is used as an advanced switching power supply technology, and has been widely accepted and applied in the field of high-power supply application due to the remarkable low-switching loss characteristic. In a power electronic system, an LLC resonant circuit can realize zero voltage turn-on (ZVS) of a switching tube, so that the switching loss is greatly reduced, and the system efficiency is improved, thereby being an ideal choice in a high-power scene. However, there are some significant disadvantages to the transformer structure used in conventional LLC resonant circuits. These conventional transformers typically employ conventional magnetic core and winding structures, resulting in limitations in several aspects: First, the window utilization of the conventional transformer structure is low. In conventional EE, EI, or other shaped cores, there is a significant waste of winding fill space and core window area cannot be fully utilized. This inefficient use of space results in the need for a larger size core at the same power level, directly affecting the overall volume of the transformer. Secondly, the finished structure of conventional transformers is generally large. Due to the limitations of winding design, plus the additional space required to meet insulation requirements, conventional transformers tend to be bulky in high power applications. Particularly in the context of AC-DC conversion, the transformer size is further increased in order to meet the stringent requirements of safety standards for insulation. In addition, the bulk of the conventional transformer directly leads to an increase in the overall size of the power module. With the trend of miniaturization and weight reduction of modern electronic systems, the volume of the power module becomes a bottleneck limiting the integration level of the system. The large transformer occupies precious space resources, and limits the layout flexibility of the power module and the design freedom of the whole machine. In summary, the conventional switch power transformer structure has defects in window utilization, volume, space occupation, heat dissipation and the like, which results in larger power module size and higher cost, and is difficult to meet the requirements of the modern high-power density power supply system. These problems restrict popularization and application of LLC resonant topology in more high power density application scenarios, and development of a novel transformer structure is needed to solve these technical bottlenecks. Disclosure of utility model The utility model aims to solve the defects in the prior art, and provides an ultrathin high-power LLC resonant main transformer for a module power supply. In order to achieve the above purpose, the present utility model adopts the following technical scheme: an ultrathin high-power LLC resonant main transformer for a module power supply, comprising: ER-type wide temperature low loss planar magnetic core; A primary side wire cake wound on the magnetic core; the secondary copper sheet is arranged on the magnetic core; the original edge wire cake adopts a special three-layer wire structure; the secondary copper sheet is led out through copper nails to form SMT mounting pins. Further, the magnetic core is of an ER-type flat plate structure and has the characteristic of flat upper and lower surfaces. Further, the three-layer wire structure of the primary side wire cake comprises a plurality of layers of insulating materials at the periphery of the conductor for enhancing the insulating property between the primary side and the secondary side. Further, the thickness of the secondary copper sheet is designed according to the output current. Further, the volume of the transformer is reduced by 1/3 to 1/2 compared with the traditional transformer with the same power. Further, the transformer is suitable for a power range of 500W to 6 KW. The beneficial effects of the utility model are as follows: 1. The special ER type flat magnetic core is adopted, the window utilization rate is improved, the whole volume is reduced, the primary side adopts a special three-layer wire cake structure, the insulation performance is improved, the safety standard requirement is met, the secondary side adopts an optimally designed copper sheet structure, the conductor loss is reduced, the heat dissipation capacity is improved, the whole flat design is realized, the upper surface and the lower surface are flat and are convenient to combine with a radiator, the heat dissipation efficiency is improved, the volume is reduced by 1/3-1/2 under the same power condition, the power density is obviously improved, the assembly efficiency