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JP-7854609-B2 - Transformer and its manufacturing method, charging device and power supply device

JP7854609B2JP 7854609 B2JP7854609 B2JP 7854609B2JP-7854609-B2

Inventors

  • 山川 岳彦
  • 松本 啓
  • 中村 進
  • 宮本 豊

Assignees

  • パナソニックＩＰマネジメント株式会社

Dates

Publication Date
20260507
Application Date
20201210
Priority Date
20191211

Claims (15)

  1. A transformer having a primary winding and a secondary winding, comprising a first core and a second core arranged so as to pass through the primary winding and the secondary winding and face each other, The first core includes one first core portion, The second core includes a plurality of second core portions, The second core is configured to have the primary winding and the secondary winding , which are wound on a single bobbin, inserted through it. The first core portion is an E-type core, Each of the second core sections is a U-shaped core, The second core portions are each arranged with respect to a heat-resistant elastic material, transformer.
  2. The system further comprises a cooling device located below the first core. The transformer according to claim 1.
  3. A transformer having a primary winding and a secondary winding, comprising a first core and a second core arranged so as to pass through the primary winding and the secondary winding and face each other, The first core includes one first core portion, The second core includes a plurality of second core portions, The second core is configured to have the primary winding and the secondary winding , which are wound on a single bobbin, inserted through it. The first core portion is an E-type core, Each of the second core sections is a U-shaped core, The system further comprises a cooling device located below the first core. transformer.
  4. The first core is the lower core, The second core is the upper core. A transformer according to any one of claims 1 to 3 .
  5. The first core and the second core are arranged to face each other with a gap in between. A transformer according to any one of claims 1 to 4 .
  6. The first core and the second core are arranged facing each other, with a heat-resistant elastic material included in the gap between them. The transformer according to claim 5 .
  7. The first core and the second core are bonded to each other and arranged to face each other. A transformer according to any one of claims 1 to 6 .
  8. The first core and the second core are positioned facing each other and are fixed to each other with adhesive tape. A transformer according to any one of claims 1 to 6 .
  9. A charging device that supplies a charging voltage to a rechargeable battery, A transformer comprising the transformer described in any one of claims 1 to 8, Charging device.
  10. A power supply device that supplies power voltage to a load, A transformer comprising the transformer described in any one of claims 1 to 8, power supply.
  11. A method for manufacturing a transformer having a primary winding and a secondary winding, and comprising a first core and a second core, The steps include inserting the primary winding and the secondary winding , which are wound on a single bobbin , into the second core, which includes a plurality of second core portions, The steps include arranging the two core portions relative to each other via a heat-resistant elastic material, The process includes the step of inserting the first core through the primary winding and the secondary winding so that the first core faces the second core, The first core is an E-type core, Each of the second core sections is a U-shaped core. A method for manufacturing transformers.
  12. The further step includes arranging a cooling device below the first core, A method for manufacturing a transformer according to claim 11.
  13. A method for manufacturing a transformer having a primary winding and a secondary winding, and comprising a first core and a second core, The steps include inserting the primary winding and the secondary winding , which are wound on a single bobbin , into the second core, which includes a plurality of second core portions, The steps include inserting the first core through the primary winding and the secondary winding so that the first core faces the second core , The process includes the step of placing a cooling device below the first core, The first core is an E-type core, Each of the second core sections is a U-shaped core. A method for manufacturing transformers.
  14. The step of arranging the first core to face the second core is: This includes arranging the first core and the second core so that they are bonded to each other and facing each other. A method for manufacturing a transformer according to any one of claims 11 to 13 .
  15. The step of arranging the first core to face the second core is: The first core and the second core are fixed to each other with adhesive tape while being positioned facing each other. A method for manufacturing a transformer according to any one of claims 11 to 13 .

Description

This disclosure relates to a transformer used in a power conversion circuit such as a DC-DC converter, a charging device using the transformer, a power supply device using the transformer, and a method for manufacturing the transformer. Conventionally, electric vehicles and plug-in hybrid vehicles are equipped with on-board charging devices for charging rechargeable batteries from commercial AC power sources. For example, these are disclosed in Patent Documents 1 and 2. Patent Document 1 discloses a transformer in which E-type cores are combined vertically. Patent Document 2 discloses a transformer in which the inner legs are divided from the center and a heat sink is interposed between them, in an external iron type transformer. Japanese Patent Publication No. 2013-131540Patent No. 5974833 This is a block diagram showing an example of the configuration of an in-vehicle charging device 101 according to the present disclosure.Figure 1 is a circuit diagram showing an example configuration of the LLC resonant DC-DC converter 105.Figure 2 is a perspective view showing the external appearance of the transformer 206.This is a longitudinal cross-sectional view along the line A-A' in Figure 3.This is a cross-sectional view along the line B-B' in Figure 3.This is a magnified vertical cross-sectional view showing the strain that occurs in the core when a temperature difference occurs between the upper and lower cores of a conventional transformer.This is a longitudinal cross-sectional view of the transformer 206 in Figure 1 when it is fixed with adhesive 404.This is a longitudinal cross-sectional view of the transformer 206 in Figure 2 when it is fixed with adhesive tape 701.This is a longitudinal cross-sectional view of the transformer 206 in Figure 2 when its entire circumference is fixed with adhesive tape 701.Figure 2 is a perspective view showing the appearance of the transformer 206 when its entire circumference is fixed with adhesive tape 701.This is a longitudinal cross-sectional view of the transformer 206 shown in Figure 2, where a heat-resistant elastic material 801 is interposed between the core portions 303a and 303b of the U-shaped core and fixed with adhesive tape 701.Figure 2 is a longitudinal cross-sectional view of the transformer 206 when a heat-resistant elastic material 901 is interposed between the core portions 303a and 303b of the two U-shaped cores and the lower core 302 of the E-shaped core, and fixed with adhesive tape 701.This is a longitudinal cross-sectional view showing an example of the configuration of a transformer 206A according to Modification 1, which is composed of one I-shaped core 302A and two U-shaped cores 303Aa and 303Ab.This is a longitudinal cross-sectional view showing an example of the configuration of a transformer 206B according to Modification 2, which is composed of one T-shaped core 302B and two L-shaped cores 303Ba and 303Bb.This is a longitudinal cross-sectional view showing the first process in the manufacturing process of the transformer 206 shown in Figure 6.This is a longitudinal cross-sectional view showing the second process in the manufacturing process of the transformer 206 shown in Figure 6.This is a longitudinal cross-sectional view showing the third process in the manufacturing process of the transformer 206 shown in Figure 6.This is a longitudinal cross-sectional view showing the fourth process in the manufacturing process of the transformer 206 shown in Figure 6.This is a longitudinal cross-sectional view showing the fifth process in the manufacturing process of the transformer 206 shown in Figure 6.Figure 7C is a longitudinal cross-sectional view showing the first process in the manufacturing process of the transformer 206.Figure 7C is a longitudinal cross-sectional view showing the second process in the manufacturing process of the transformer 206.Figure 7C is a longitudinal cross-sectional view showing the third process in the manufacturing process of the transformer 206.Figure 7C is a longitudinal cross-sectional view showing the fourth process in the manufacturing process of the transformer 206.Figure 7C is a longitudinal cross-sectional view showing the fifth process in the manufacturing process of the transformer 206.This is a perspective view showing the external appearance of a transformer 206C according to Modification 3, which is composed of a lower core 302 of a single U-shaped core and an upper core 303 of an E-shaped core consisting of four divided core sections 303a, 303b, 303c, and 303d. Industrial application fields The embodiments of this disclosure will be described below with reference to the drawings. (Problems with the comparative example) Hereinafter, the transformer disclosed in Patent Document 1 will be referred to as Comparative Example 1, and the transformer disclosed in Patent Document 2 will be referred to as Comparative Example 2, and their problems will be explained. As in Comparative Example 1, in a transformer with E-t